Human Factors and Ergonomics in Manufacturing & Service Industries

Case Studies of Robots and Automation as Health/Safety Interventions in Small Manufacturing Enterprises
Lowe BD, Hayden M, Albers J and Naber S
This paper reviews the experiences of 63 case studies of small businesses (< 250 employees) with manufacturing automation equipment acquired through a health/safety intervention grant program. The review scope included equipment technologies classified as industrial robots (n = 17), computer numerical control (CNC) machining (n = 29), or other programmable automation systems (n = 17). Descriptions of workers' compensation (WC) claim injuries and identified risk factors that motivated acquisition of the equipment were extracted from grant applications. Other aspects of the employer experiences, including qualitative and quantitative assessment of effects on risk factors for musculoskeletal disorders (MSD), effects on productivity, and employee acceptance of the intervention were summarized from the case study reports. Case studies associated with a combination of large reduction in risk factors, lower cost per affected employee, and reported increases in productivity were: CNC stone cutting system, CNC/vertical machining system, automated system for bottling, CNC/routing system for plastics products manufacturing, and a CNC/Cutting system for vinyl/carpet. Six case studies of industrial robots reported quantitative reductions in MSD risk factors in these diverse manufacturing industries: Snack Foods; Photographic Film, Paper, Plate, and Chemical; Machine Shops; Leather Good and Allied Products; Plastic Products; and Iron and Steel Forging. This review of health/safety intervention case studies indicates that advanced (programmable) manufacturing automation, including industrial robots, reduced workplace musculoskeletal risk factors and improved process productivity in most cases.
Coping with complexity in the COVID pandemic: An exploratory study of intensive care units
Saurin TA, Wachs P, Bueno WP, de Souza Kuchenbecker R, Boniatti MM, Zani CM and Clay-Williams R
Although the COVID pandemic has challenged the resilience of health services in general, this impact has been most visible in intensive care units (ICUs). This paper presents an exploratory study of how ICUs in Brazil have coped with the complexity stemming from the pandemic. Five guidelines for coping with complexity were adopted as analytical framework. The guidelines were concerned with slack resources, diversity of perspectives, visibility, work-as-done, and unintended consequences. There were three main sources of data: (i) a survey with respondents from 33 ICUs, which indicated their agreement with 23 statements related to the use of the complexity guidelines; (ii) semistructured interviews with seven survey respondents and two public health officials; and (iii) 20 h of observations of the meetings of a municipal bed management committee. Seventy resilience practices were identified from these data sources. Most of these practices ( = 30) were related to the guideline on slack resources, which were commonly obtained from other hospital units. As for the survey data, the statement related to the availability of extra or standby human resources obtained the lowest score, reinforcing the key role of slack resources. Five lessons learned for coping with complexity in ICUs were drawn from our data; one lesson for each guideline. Furthermore, the survey questionnaire is a potential ICU assessment tool, which can be adapted to other health services.
A study on usability and design parameters in face mask: Concept design of UVW face mask for COVID-19 protection
Ipaki B, Merrikhpour Z, Taheri Rizi MS and Torkashvand S
The aim of this study is to investigate the usability of conventional masks to prevent the transmission of coronavirus 2019 (COVID-19) and subsequently design the proposed concept of the mask to reduce leakage and increase efficiency. Acute respiratory syndrome COVID-19 is spreading around the world and can be transmitted from one person with COVID-19 to another through personal contact and breathing. Improper design of current masks can lead to virus transmission. One hundred fifteen users participated in the study using a simple random sampling method in which N95-FFP2 face mask and surgery face mask usability tests were chosen as the most widely used face masks in Iranian people with an online usability questionnaire. Data were analyzed by SPSS. The results showed that the usability of the N95-FFP2 face mask with a total average of 4.46 and a surgical mask with a total average of 3.35 cannot be considered acceptable. Anthropometric and formal changes in people's faces and improper design of the face masks used make it necessary to review the mask redesign measures to increase the prevention of pathogens. In this study, new parameters for face mask design are proposed. Thirty different types of jaws have been considered with the help of CorelDRAW software, along with ideas for optimal mask design with UVW mask concept to be accessed by manufacturers around the world.
Integration of human factors/ergonomics in healthcare systems: A giant leap in safety as a key strategy during Covid-19
Rodríguez Y and Hignett S
In this article, we present a model for integrating Human Factors/Ergonomics (HFE) into healthcare systems to make them more robust and resilient. We believe that to increase the impact of HFE during and after the Covid-19 pandemic this integration should be carried out simultaneously at all levels (micro, meso, and macro) of the healthcare system. This new model recognizes the interrelationship between HFE and other system characteristics such as capacity, coverage, robustness, integrity, and resilience. We hope that the model will serve as a reference for a giant leap to design and improve the safety and effectiveness of healthcare services from a holistic (systems) perspective.
A systematic review on the impacts of Covid-19 on work: Contributions and a path forward from the perspectives of ergonomics and psychodynamics of work
Sigahi TFAC, Kawasaki BC, Bolis I and Morioka SN
Work is a major issue in the discussions on the Covid-19 pandemic, whose consequences impair the capacities of workers at all organizational levels and impose unexpected challenges on managers. Nevertheless, the scientific literature still lacks an overview of how researchers have been covering the issue. This article presents a systematic review to investigate the impact of Covid-19 on work and workers of all occupations, reveal research gaps, and help managers to adapt to organizations amid the pandemic. This review is based on a sample of 258 papers from Web of Science and Scopus databases. Quantitative and qualitative analysis indicated a vast majority of studies focused on frontline healthcare workers and a lack of empirical investigation on managers' work. We show how literature has been addressing different aspects of work (e.g., workers' health, working conditions, procedures, protection equipment, remote working, etc.) in the various economic sectors. We discuss the results in light of ergonomics and psychodynamics of work, two disciplines that conceive work and organization as intimately connected, and that can assist managers in meeting the difficulties brought by the pandemic. We highlight that considering the construction of health, interindividual variability, subjective relation to work, supportive workplace environment, and organizational and individual capabilities can play a key role in successfully adapting and transforming organizations in the current scenario.
Impact of COVID-19 on health and safety in the construction sector
Stiles S, Golightly D and Ryan B
Construction has been significantly affected by COVID-19 yet is critical to the post-COVID economic recovery. Specifically, construction needs to be constantly aware of safety and risk balanced with timely project delivery. Guidance for COVID-19 must therefore be implemented in a way that reflects working practice and pressures. There is, however, a potential knowledge gap regarding the practical feasibility and impact of applying COVID-19 measures within construction, made more difficult by factors such as the temporary nature of projects and complex working arrangements. This article presents a commentary on safe construction during, and beyond, COVID-19, covering the human factors challenges and practicalities of implementing COVID-19 measures. We observe that while guidance is strong on risk management, understanding of how best to implement this guidance is not yet stable. Also, care must be taken that implementing guidance does not detract from general safety, which is also challenged by increased pressures on delivery arising from COVID-19. There may, however, be opportunities for safer working practice arising from new awareness of health, hygiene, and safety risk. The role of safety leadership is overlooked in guidance yet is vital to ensure safe application of COVID-19 working practices. The key message is that COVID-19 needs to be integrated and promoted within a general risk management approach, in part because this takes account of differing priorities regarding safety risks, rather than overly focussing on COVID-19, and also because the effectiveness of COVID-19 mitigations can be amplified by integration with pre-existing safety processes.
Aiding decision makers to reopening of places of worship
Rothrock L, Abraham A, Graf A, Rodopman M and Nold D
Our research objective is to work with leaders of houses of worship in the local community to assess options for the physically reopening of places of worship.
Ghost trains: Australian rail in the early stages of the global COVID-19 pandemic
Naweed A, Jackson JE and Read GJM
The rail industry, as with all sectors worldwide, has faced disruptions due to the global COVID-19 pandemic. This commentary considers how rail organizations in Australia have engaged within the early stages of the crisis, outlining the challenges faced and how they were addressed. Relying on our observations, and anecdotes obtained from others across the Australian rail industry, we identified a range of impacts including determining service delivery levels (and the associated running of "ghost trains"), implementing hygiene measures and social distancing, managing training and medical assessments, and changes in the behavior of passengers and members of the public (including aggression toward staff and increased instances of trespass). Within rail organizations, we saw changes to communication and control structures, new challenges related to balancing priorities (managing risk of rail accidents vs. virus transmission risk), and negative impacts on job design offset by increased informal support for frontline workers. Importantly, from the crisis, we gained new insights about culture. Finally, we provide recommendations regarding how the Human Factors and Ergonomics discipline can support safe and effective rail operations in the context of both widespread crises such as pandemics as well as the less dramatic, but ever present, shifts in the physical, social, economic, and political environments in which rail organizations operate.
Human Factors and Ergonomics and the management of existential threats: A work domain analysis of a COVID-19 return from lockdown restrictions system
Salmon PM, Stevens N, McLean S, Hulme A and Read GJM
Following strict "lockdown" restrictions designed to control the spread of the COVID-19 virus, many jurisdictions are now engaged in a process of easing restrictions in an attempt to stimulate economic and social activity while continuing to suppress virus transmission. This is challenging and complex, and in several regions, new outbreaks have emerged. We argue that systems Human Factors and Ergonomics methods can assist in understanding and optimizing the return from lockdown. To demonstrate, we used work domain analysis to develop an abstraction hierarchy model of a generic "return from lockdown restrictions" system. The model was assessed to identify (a) issues preventing a successful return from lockdown; and (b) leverage points that could be exploited to optimize future processes. The findings show that the aim of continuing to suppress virus transmission conflicts with the aims of returning to pre-virus economic and social activity levels. As a result, many functions act against each other, ensuring that the system cannot optimally achieve all three of its primary aims. Potential leverage points include modifying the goals and rules of the system and enhancing communications and feedback. Specifically, it is argued that moderating economic aims and modifying how social and community activities are undertaken will result in longer term suppression of the virus.
The adaptive capacity of public space under COVID-19: Exploring urban design interventions through a sociotechnical systems approach
Stevens NJ, Tavares SG and Salmon PM
The coronavirus disease 2019 (COVID-19) pandemic has had a dramatic impact on the way in which the community interacts within public spaces. Consequently, the design of these urban environments requires new approaches. It is our view that Human Factors and Ergonomics approaches can be used to provide these insights. This article explores the opportunities for making public spaces safer and more accessible for community use under pandemic conditions. The study utilizes a sociotechnical systems model of an archetype public space, developed pre-COVID-19, to explore the infrastructure and activities that are impacted by the introduction of the virus to the public space system. The aim was to identify those elements of the system that are completely unavailable under pandemic conditions, those elements that become limited in use, and those which remained unaffected by the presence of the virus. The findings show that under pandemic conditions pre-COVID-19 public spaces were surprisingly resilient with proportionally few elements within the model completely unavailable. They also demonstrate that overall, the public spaces system, while still operating, is significantly constrained in achieving and optimizing community and individual health and well-being. The insertion of five (5) urban design interventions within the system model presented unique insights into the possibilities for optimizing adaptive capacity. These interventions revealed design opportunities across several levels of the systems model. Such insights are argued to assist in not only re-establishing community access under pandemic conditions but also more inclusive access to a broader range of the community under all conditions.
Development of a novel hybrid cognitive model validation framework for implementation under COVID-19 restrictions
Stone PB, Nelson HM, Fendley ME and Ganapathy S
The purpose of this study was to develop a method for validation of cognitive models consistent with the remote working situation arising from COVID-19 restrictions in place in Spring 2020. We propose a framework for validation tasks and a scoring system to determine initial model validity. We infer an objective validity level for cognitive models requiring no in-person observations, and minimal reliance on remote usability and observational studies. This approach has been derived from the necessity of the COVID-19 response, however, we believe this approach can lower costs and reduce timelines to initial validation in post-Covid-19 studies, enabling faster progress in the development of cognitive engineering systems. A three-stage hybrid validation framework was developed based on existing validation methods and was adapted to enable compliance with the specific limitations derived from COVID-19 response restrictions. This validation method includes elements of argument-based validation combined with a cognitive walkthrough analysis, and reflexivity assessments. We conducted a case study of the proposed framework on a developmental cognitive model of cardiovascular surgery to demonstrate application of a real-world validation task. This framework can be easily and quickly implemented by a small research team and provides a structured validation method to increase confidence in assumptions as well as to provide evidence to support validity claims in the early stages of model development.
A heuristic international glimpse at SARS-CoV-2 effects on work-home equilibrium and women
Gulotta CJ, Madeira-Revell K and Fendley ME
This article takes a condensed look at the impact that SARS-CoV-2 has had on the work-life balance of women engineers across the world in industry, military and academia. The same impact has been felt by all women, not only in science, as it is this gender status that inevitably ties women together, facing the same challenges, and cannot be separated by category of employment, or lack thereof. Studies from around the world give us insight into how the pandemic has instigated changes and influenced choices made between work and domestic demands. Globally, women are burdened with challenges that may compromise their progression in male-dominated fields, such as engineering. Taking a glimpse at this issue for women through an international lens, we identify potential human factors methods to respond to this global problem, offering tools and forewarnings for improving our efforts in designing for, and maintaining equilibrium for women in engineering, technology, academia, and beyond.
A novel distance learning ergonomics checklist and risk evaluation methodology: A case of Covid-19 pandemic
Ayyildiz E and Taskin Gumus A
Many governments decided to cancel face-to-face teaching and learning activities in schools and universities. They replaced them with online teaching and distance learning activities to prevent the spread of Coronavirus disease 2019 (COVID-19). Due to this sudden change, students experienced some anthropometric, environmental, and psychosocial difficulties at home during the distance learning process. This study focuses on determining the importance of anthropometric, environmental, and psychosocial factors in the distance learning process during the COVID-19 pandemic. This study presents main factors and their subfactors affecting ergonomic conditions of university students during distance learning. A novel distance learning ergonomics checklist is proposed based on the Occupational Safety and Health Administration checklists. The data are collected via a questionnaire filled by 100 university students who attend the Ergonomics course online. Then, the integrated methodology includes Voting Analytic Hierarchy Process integrated Pythagorean Fuzzy Technique for Order Preference by Similarity to An Ideal Solution method is adopted to prioritize the factors determined. Thirty-nine different subfactors are evaluated under five titles, and the most important factors are determined using the proposed methodology. With the results achieved, it is seen that the suggested checklist and proposed methodology can be used by public and private education organizations as a guide for improving their distance learning strategies.
Safety culture transformation-The impact of training on explicit and implicit safety attitudes
Marquardt N, Hoebel M and Lud D
The present paper investigates the changeability of safety culture elements such as explicit and implicit safety attitudes by training. Therefore, three studies with different time frames, training durations, and settings will be presented. In the first study, the short-term attitude change of students from an international environmental sciences study program was measured after safety training in a chemical laboratory. In the second study, the medium-term attitude change was assessed after a Crew Resource Management training for German production workers in the automotive industry. In the third study, the long-term attitude changes were measured after safety ethics training in a sample of German occupational psychology and business students. Different self-report measures were used to evaluate the training effectiveness of explicit safety attitudes. The change of implicit safety attitudes was assessed by Implicit Association Tests. The results of all three studies revealed a significant training effect on the explicit safety attitudes, but not on the implicit ones. Besides the training effect on the explicit attitudes, there was no effect of time frame (short-, medium-, long-term), training duration (2 h, 2 days, 12 weeks), and setting (chemical laboratory, automotive industry, safety ethics study program) on the attitude change. Based on the results, conceptual, methodological, and practical implications for training effectiveness and safety culture transformation are discussed.
Development of Human Posture Simulation Method for Assessing Posture Angles and Spinal Loads
Lu ML, Waters T and Werren D
Video-based posture analysis employing a biomechanical model is gaining a growing popularity for ergonomic assessments. A human posture simulation method of estimating multiple body postural angles and spinal loads from a video record was developed to expedite ergonomic assessments. The method was evaluated by a repeated measures study design with three trunk flexion levels, two lift asymmetry levels, three viewing angles and three trial repetitions as experimental factors. The study comprised two phases evaluating the accuracy of simulating self and other people's lifting posture via a proxy of a computer-generated humanoid. The mean values of the accuracy of simulating self and humanoid postures were 12° and 15°, respectively. The repeatability of the method for the same lifting condition was excellent (~2°). The least simulation error was associated with side viewing angle. The estimated back compressive force and moment, calculated by a three dimensional biomechanical model, exhibited a range of 5% underestimation. The posture simulation method enables researchers to simultaneously quantify body posture angles and spinal loading variables with accuracy and precision comparable to on-screen posture matching methods.
Do Alcohol Warning Labels Influence Men's and Women's Attempts to Deter Others from Driving When Intoxicated?
Tam TW and Greenfield TK
Research on the federally mandated alcohol warning label has found mixed results, but some findings are consistent with a modest influence on precautionary behaviors to reduce drinkers' self-reported drunk driving. We hypothesized that warnings would also influence the likelihood of intervening to deter other's driving after drinking. Using data from 1376 adult drinkers in a US national survey, a conceptual model reflecting effects of exposure to the label's drunk driving message on taking actions to avert another's driving under the influence was tested in a structural equation modeling framework. For males and females, in structural models with drinking and handling of alcoholic beverages potentially affecting both message recall and intervening, the predicted relationships were found between message recall and actions to deter another's drinking driving. This finding suggests that an important preventive effect of the alcohol warning label may be to legitimate collateral's attempts to avert another's drunk driving.
The Employability of Older Workers as Teleworkers: An Appraisal of Issues and an Empirical Study
Sharit J, Czaja SJ, Hernandez MA and Nair SN
The aging of the population and, concomitantly, of the workforce has a number of important implications for governments, businesses, and workers. In this article, we examine the prospects for the employability of older workers as home-based teleworkers. This alternative work could accommodate many of the needs and preferences of older workers and at the same time benefit organizations. However, before telework can be considered a viable work option for many older workers there are a number of issues to consider, including the ability of older workers to adapt to the technological demands that are typically associated with telework jobs and managerial attitudes about older workers and about telework. Through an integrated examination of these and other issues, our goal is to provide a comprehensive understanding of the challenges associated with employing older workers as teleworkers. We also present findings from a questionnaire study that assessed managers' perceptions of worker attributes desirable for telework and how older workers compare to younger workers on these attributes. The sample included 314 managers with varying degrees of managerial experience from a large variety of companies in the United States. The results presented a mixed picture with respect to the employability of older workers as teleworkers, and strongly suggested that less experienced managers would be more resistant to hiring older people as teleworkers. We conclude with a number of recommendations for improving the prospects for employment of older workers for this type of work arrangement.