SECOND EDITION THE RULES OF WORK A Practical Engineering Guide to Ergonomics SECOND EDITION THE RULES OF WORK A Practical Engineering Guide to Ergonomics SECOND EDITION by Dan MacLeod K14336_FM.indd 3 9/19/12 3:44:41 PM CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2013 by Dan MacLeod CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 2012918 International Standard Book Number-13: 978-1-4665-6025-3 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. 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CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com v Contents: Author vii Acknowledgments ix Preface xi PartI 111eRulBs Introduction- Overview ofthefield 3 1. Posture 17 2. Force 21 3. Reach 33 4. Heights 38 5. Motions 42 6. Fatigue 47 7. PressurePoints .52 8. Clearance 55 9. Movement andchange 57 10.Environment 59 11.Applications 62 12.Cognitive Ergonomics 82 13.Work Organization 89 Part1/ MeasulfJmentsandGuldel/nes Introduction- Why measure? 95 14.Anthropometry 98 15.Exertionand Biomechanics 110 16.Posture 121 17.Motions 125 18.Miscellaneous 130 19.NIOSH LiftingGuide 134 20. Puahing, Pulling, and CarryingGuides 144 21. RapidUpperLimbAssessment (RULA) 146 22. Strain Index 150 23. Time and Physical DemandsAnalysis (fAPDA) 151 24. EmployeeDiscomfortSurveys 152 25.Stodies 154 26. Problem-SolvingProcess 169 References 179 Index 182 vii AbouttheAuthor Dan MacLeod is one of the leading practitioners of workplace ergonomics, widelyrecognized for his down-to-earth approach and his emphasis on low-cost, low-tech job improvements. He served as a consultant to employers, trade associations. and unions for over 35 years, and has developed innovative corporate programs that have resulted in thousands of ergonomic improvements and savings of millions of dollars. In all,he has conducted evaluations in over 1500 workplaces in his lifetime. assessing thousands of individual tasks. He was instrumental in the late 1970s in recognizing the widespread impact of work-related musculoskeletal disorders. In 1982, he authored the first lay lauguage training materials in North America on workplace ergonomics. He has comprehensive experience in multiple industries, ranging from offices and hospitals to underground mining and steel mills. He has worked with small organizations as well as some of the largest corporations inthe U.S. His work has helped change entire industries. In the late 1970s, he pioneered the first workplace ergonomics programs in car assembly operations. In the 19808.he was heavily involved in the meatpacklng industry, where he represented the industry in working with OSHA to develop the Ergonomics Guidelinesforthe Meatpacking Industry. Dan is multilingual with broad international consulting expe rience, especially in China and Mexico. He is a Certified Profes sional Ergonomist (CPE) and holds master's degrees in both occupational health and industrial relations. He works as an inde pendent consultant; see www.danmacleod.com. ix Acknowledgments Conlonl- Everything in this book is based on whatI have learned working on-site in plants and with client organizations. In the process, lowe much to many very bright and helpful people throughout the years, including: Peter Budnick, Jessica Waller, Mark Weare, Mike Allen, Jeff Ware, Eric Kennedy, Wayne Adams, Elizabeth Damann, Rob Nerhood Il, Ioe Pallansch, Don Chaffin, Tom Armstrong, Rob Radwin, Rich Marklin, Don Bloswick, Stover Snook, Bob Bozzay, Bill Boyd, Lois Hensley, DonHirsch, TomBray, and Devin Lackie. Eric Kennedy and Wayne Adams especially provided considerable support in the initial development of the section on quantitative methods. Layonland design - The author. lIIustntlonl - Michelle Deiber Kumm supplemented previous drawingsbyMaryNoyes, MarkWatson, and TomNynas. Coverart- KirklandBray, adapted from LarsNormann. ToBertrande