Plant ergonomics

Plant Ergonomics checklist walk-through Investigator observes ergonomics and productivity, verified by operator... 

Kristal-Boneh, E., Harari, G., Gieen, M. S. (1997). Heart rate response to industrial work at different outdoor temperatures with or without control systems at the plant. Ergonomics, 40, 729-736. 

The layout of the instmmentation and the mode of presentation of information shall provide the operating personnel with an adequate overall picture of the status and performance of the plant. Ergonomic factors shall be taken into accoimt in the design of the control room. 

Your procedures should detail your plant evaluation methods and require consideration to be given to the overall plan of the plant, automation, ergonomics, operator and line balance, inventory levels, and value added labor content. Reports of the evaluation should be required so that they facilitate analysis by management and auditors. 

Inadequate ergonomic design in areas such as control panels and the labeling and placement of valves on the plant can also be regarded as a latent failure because it will increase the probability of active errors. For example, a worker may misread process information from a poorly designed display. Poorly labeled and situated valves can cause the wrong valve to be selected, with possibly disastrous consequences. 

Root causes 6, 7, and 8. Human factors aspects were inadequately addressed. Specifically, ergonomics of the plant was poor, there were differences in layout among different areas and the labeling was poor. 

Marshall, E. C., Duncan, K. D., Baker, S. M. (1981). The Role of Withheld Information in the Training of Process Plant Fault Diagnosis. Ergonomics 24,711-724. 

Equipment should be chosen so, that it can be easily seen, wheather it has been installed correctly or wheather it is in the open or shut position. This refers to ergonomics of the plant. Also clear explanation of the chemistry involved in the process helps operating personnel to identify possible hazards. 

Hazards may also result from the interaction between company employees and the work environment these are called "ergonomic" hazards. If the physical, psychological, or environmental demands on workers exceed their capabilities, an ergonomic hazard exists. These hazards, in themselves may lead to fiirther major incidents when the individual cannot perform properly under stress during critical periods of plant... 

HANGARTNER, M., Sampling and Analysis of Odorous Compounds in Water Treatment Plants. Institute of Hygiene and Ergonomics, Swiss Federal Institute of Technology, 8092 Zurich, Switzerland. 

This safety audit is used for identifying inputs and material flows, processes and intermediates, and final products - but with special attention paid to human-material/process/equipment interactions that could result in (a) sudden and accidental releases/spills, (b) mechanical failure-based injuries, and (c) physical injuries - cuts, abrasions, and so on, as well as ergonomic hazards. Additional sources of adverse effects/safety problem areas are records/ knowledge of in-plant accidents/near misses, equipment failures, customer complaints, inadequate secondary prevention/safety procedures and equipment (including components that can be rendered non-operable upon unanticipated events), and inadequacies in suppliers of material and equipment or maintenance services. 

These examples along with others show that the causes of these incidents were not only because of ergonomic factors but also because of the failure of the equipment or some other unknown reasons. The breakdown of these incidents was probably a lack of safety measures for the plant workers and also to the nearby communities. 

Garg, A., and Moore, J. S. (1997), Participatory Ergonomics in a Red Meat Packing Plant, Part 1 Evidence of Long Term Effectiveness, American Industrial Hygiene Association Journal, Vol. 58, No. 2, pp. 127-131. 

Joseph, B. S. (1986), A Participative Ergonomic Control Program in a U.S. Automotive Plant Evaluation and Implications, Ph.D. dissertation. University of Michigan. 

Keyserling, W. M., and Hankins, S. E. (1994), Effectiveness of Plant-Based Committees in Recognizing and Controlling Ergonomic Risk Factors Associated with Musculoskeletal Problems in the Automotive Industry, in Proceedings of the XII Congress of the International Ergonomics Association, Toronto, Vol. 3, pp. 346-348. 

Such changes in the structure of the ergonomics/human factors profession indeed demand different evaluation methodologies. A powerful network of individuals, for example, who can, and do, call for human factors input in a timely manner can help an enterprise more than a number of individually successful project outcomes. Audit programs are one of the ways in which such evaluations can be made, allowing a company to focus its human factors resources most effectively. They can also be used in a prospective, rather than retrospective, manner to help quantify the needs of the company for ergonomics/human factors. Finally, they can be used to determine which divisions, plants, departments, or even product fines are in most need of ergonomics input. 

The ergonomics program was similarly diverse. It started with a corporate launch by the highest-level executives and was rolled out to the divisions and then to individual plants. The pace of change was widely variable. AU divisions were given a standard set of workplace analysis and modification tools (based on Drury and Wick 1984) but were encouraged to develop their own solutions to problems in a way appropriate to their specific needs. 

The major user concern at the plant level was time devoted to ergonomics by providers. At the corporate level, the need was seen for more rapid job-analysis methods and corporate policies, such as on back belts or good chairs. Overall, 94% of users made positive comments about the ergonomics program. 

Occupational Safety and Health Administration (OSHA), (1990), Ergonomics Program Management Guidelines for Meatpacking Plants, Publication No. OSHA-3121, U.S. Department of Labor, Washington, DC. 

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