Ergonomic Design Guideline

WEIGHTS

Pinch Grip
(thumb & one or
more fingers or
fingers to palm)
W3 Push/pull force for
F3
assist
dolly/cart/lift
+ Push ordevices
pull with 2 or
more fingers

F4
W4
Criteria for requiring
+
Lift Assist Device
Push or pull with one
hand

F5

Table 1

FORCES

Lateral push/pull
forces

F6

Push or pull with both

hands or palms

F7

Strike with hand

F8

Control Operation
Forces

F9

Maximum Grip Force

Power Grip

Criteria
Criteria

Purpose
Purpose

Should Not
Exceed
Exceed
5 kg OR
Where repetitively lifted weights
Where
exceedthe
guideline
exceedforces
15kg and/or
NIOSH RWL
< 15kg AND
alternatives
may must
be to be
reduce
an assist device
used,the
the
<NIOSH
required
or to improve
grip Recommended
weight offorce
the object
reduced the
or an
or
surfacestd
area
greater
force may
operation
to so
require
a multiWeight Limit

3 kg
be
generated
safely.
person
lift.
(RWL)

Design Application
Application
Design

Ideal Value
Ideal Value

Typical
Part/Example
Headliner
Side member

Measurement Criteria
Measurement Criteria

References
References

For parts above 5kg, a detailed

Pushing
with
thumb of
where
surface
area
evaluation
(NIOSH)
the lift
must be
2
<30mm
(approx
area of
a finger
tip).&If a
performed
considering
height,
reach
digit
cannot be supported, a limit of 1 kg
frequency.
push is recommended.

Manual materials handling is a major

The
structure
tips
source
of risk of
to the finger/thumb
back and upper
is
not and
suitable
forlargest
absorbing
high
limbs
is the
cause
of lost
contact
stresses,
can result in
time injuries
withinwhich
the US.
injury to the nerves, tendons and
ligaments

Lifts are 2 handed with fair handholds,

symmetrical and close into the body.
Sliding scale is based upon the NIOSH
Force
to grip/manipulate/operate
(1991)required
lifting equation.
an object/tool held in a pinch grip. (Item is
"pinched" between the thumb and
finger(s))

Manual materials handling is a major

source of risk to the back and upper
limbs and is the largest cause of lost
Pinch
grips require
5 times
time injuries
within the
US. greater
muscular effort than power type grips.
High force pinch grips can typically
cause injury to the tendons in the
hand, forearm & elbow & muscle
fatigue in the hand & forearm

When determining packaging,

delivery method and storage position
consideration should be given
Design
should
consider
the in
frequency,
heights
& reaches
elimination
pinch
where it is
conjunctionof
with
the grips
weight.
possible to alter the hand to part/tool
interface to create a power type grip
or by the use of fixtures or tools

15 kg

Force required to initiate and sustain

Push
or pullofforce
that must
be generated
movement
a dolly/cart
or similar
where
to
complete
an operation
the force
both
hands are
in contact where
and are
can
only be
applied
using theheight AND
between
waist
and shoulder
fingers/thumb.
force is generated from the legs.

Manual materials handling is a major

The
structure
tips
source
of risk of
to the
the finger/thumb
back and upper
is
not and
suitable
forlargest
absorbing
high
limbs
is the
cause
of lost
contact
stresses,
can result in
time injuries
withinwhich
the US.
injury to the nerves, tendons and
ligaments

The level of force required is a

Design
consider
the
functionshould
of the weight
of reducing
the object,
required
force
creating
the size of
the or
wheels
andan
the
improved
greater
resistancehandhold
between where
the wheel
and
force
can beUsing
safelylarger,
generated
or the
the ground.
low friction
use
of
a
tool
or
fixture.
wheels can significantly reduce

15 kg
initial

Delivery carts
Single clip
(dia.>30mm)
W/harness clamp
Grommet
(dia.>30mm)

Measure using a push/pull gauge or similar

Measured
push/pull
gauge
or load
device, theusing
force arequired
firstly
to overcome
cell.
inertia and second the force required to
Measure
should reflect as closely as possible
maintain momentum
production conditions such as time required to
complete & line of force

Push force that must be generated to

complete
an operation
where
force
For parts >15kg
a lift assist
orthe
2 man
lift
can
only be
applied using
a single
hand.
(w/NAMC
approval)
is required
unless
Assumes
that the
force
is spread over the
NIOSH Lifting
Index
is <1
whole
withthan
either
a power
grip or an
flat
Some hand
lifts less
15kg
may require
hand.
assist due to reach, freq., ht., etc. Refer
Numerical
values
to
to F4, F5, F6,
or W3corresponding
for forces to initiate
knee
& shoulder heights are provided
movement.
for standing work; otherwise use knee
& shoulder as height reference points.
The initial force required moving an
object/tool where the line of force is
across the body and generated by the
upper body not the legs.

Forces applied at the hand can

generate
significant
moment
and
Manual materials
handling
is arms
a major
loading
onrisk
theto
wrist,
elbowand
andupper
source of
the back
shoulder.
the forces
limbs and Reducing
is the largest
cause of lost
required
at the
handthe
willUS.
protect the
time injuries
within
structure of these joints from injury

push/pull
forces.
Design
should
consider how force
7 kg between 7 kg between
must
be applied.
Where
Consideration
should
be forces/loads
given to
> 15kg
OR&
635
(knee)
635 (knee) & Door on/Door off.
may
exceed
the recommendations
reducing
manually
lifted weights to
Seat install
Weight
exceeds
1255mm
1255mm
enabling
use of 2 hands
will help
Interior garnish
the lowestthe
practicable
level. Where
NIOSH
(shoulder)
(shoulder)
alleviate
stress on
oneprovision
arm.
Weather strip
weights exceed
15kg
must Recommended
Exhaust pipe
be made to automate or provide an
Weight
Limit
<6kg if work ht. <4kg if work ht.
support
assist.
(RWL)
<635 (knee) or <635 (knee) or
>1255mm
>1255mm
(shoulder)
(shoulder)

Measured using a push/pull gauge or load

cell.
Establish part/sub assembly weight.
Measure
should
reflect
as closely
as possible
Use NIOSH
Lifting
equation
(Attached)
to
production
conditions
such
as time
required
to
asses the need
for a lift
assist
device
or
complete
& line of to
force
changes required
the lift e.g. reduce reach
distance.
Note: Consider forces required to operate
device

The structure of the shoulder is less

able to generate force in this direction,
causes constriction of the
muscles/tendons and puts the
muscles at a mechanical
disadvantage.

Design of workstations and tasks

4 kg

7 kg between
635 (knee) &
in front of the t/m and the direction of
1255mm
(shoulder)
any force to be applied to be directly
Material Handling
5 kg
away or toward the body (sagital
between
plane).
<635 (knee) or
>1255mm

Sliding scale
from
15 Kg max
based
on freq. &
height
See
Table
<1
kgf 1

(modified from
original 300N
Ringi)

< 15kgf initial

< 10kgf
sustained

should
aim to place the workJobs
directly
Use to estimate
Conveyance

16
15Consideration must be given to the
Push force that must be generated to
Forces applied at the hand can
14interface between the hands and
complete an operation where the force
generate significant moment arms and
can be applied using both hands.
loading on the wrist, elbow and
Poor grip or unequal division
13object.
Assumes that the force is spread over the shoulder. Reducing the forces
of the load between hands can
whole of the hands with either a power
required at the hand will protect the
impede performance.
grip or flat hand.
structure of these joints from injury 12It is preferable for forces to be
Numerical values corresponding to
between knee and
11generated
knee & shoulder heights are provided
shoulder heights, where body weight
for standing work; otherwise use knee
10can also be applied.
& shoulder as height reference pts.
9
Hand should never be used as a hammer Impact stresses on the hand can lead Forces within the guidelines will
to the damage of the nerves and
the need to generate high
8prevent
blood vessels lying close to the
impact forces. Where such forces
surface and lead to conditions such as7cannot be avoided provision should
Hypothenar Hammer Syndrome
be made for suitable tooling.
Requirements for machinery designers, The repetitive operation of buttons, 6Machinery/eqpt design must
where controls are operated as part of a switches, levers etc places stress on consider the suitability of the
production cycle.
the tendons and ligaments and can 5controls.
compress nerves.
levers the length of the lever arm
4For
may be increased to reduce forces.
3
2
1
0Handles should be designed to
Force required to grip/manipulate/operate High grip forces cannot be done
an object/tool measured at the hand

3 kg

< 1 kgf

repetitively without increased risk of

hand, wrist or forearm injury. The
small muscles of the hand are not
capable of generating/maintaining
high forces for extended periods

0 10the required
20 30 grip
40 force.
50 For
60
minimize
example high friction finishes or end
stops reduce the grip force required
to hold and manipulate an object or
tool

Weights -

(shoulder)

10 kgf
between
635 (knee) &
1255mm
(shoulder)
<6kgf if work
ht.
<635 (knee) or
>1255mm
(shoulder)
NOT ALLOWED
Buttons pressed with fingertips
1
Toggle Switches
1
Crank handle (up to 80mm dia.)
4
Handwheels (200 - 500mm dia.)
7
One Hand
Two Hands
10
Clamps or levers (one hand)
7
Clamps or levers operated at or
4
above shoulder height
Not recommended for
standing repetitive
Foot Pedal
Operations. Where
unavoidable 5.5
Foot Switch
2.5

70

Single clip
Grommet

Establish part/sub assembly weight.

Measured
a push/pull
or load
Use NIOSHusing
Lifting
equation gauge
(Attached)
to
cell.
asses the need for a lift assist device or
Measure
should reflect
as possible
changes required
to theas
liftclosely
e.g. reduce
reach
production
distance. conditions such as time required to
complete & line of force

Small parts route Establish the weight and required frequency

Lane delivery and refer to attached Table 1.

Clamp (clip)

Measured using a push/pull gauge or load

cell.
Measure should reflect as closely as possible
production conditions such as time required to
complete & line of force

NIOSH (Waters et al., 1993),

A Guide
to Manual
Material
Handling, Mital,
TMC
Ergonomic
Manual,
2001
Nicholson,
Ayoub, 1993
Hand
Wrist &Cumulative
Trauma Disorders in
Snook & (Silverstein,
Ciriello, 1991
Industry
1986)
Manual
Handling of
Regulations,
UK
Government
The
Ergonomics
Workspaces
and
Machines,
Legislation,
1992 1995
Corlett
and Clark,
Recommended
Maximum
Permissible
Weights for
Bodyspace, Pheasant, 1998
Occasional
ILO, 1962
Ergo
DesignLifts,
for People
at Work, E. Kodak, 1986
SLAMII
Modeling
of NIOSH,
Karwowski & Gaddie,
MOD
00-25,
UK Military
Standards
Handbook
of Human
Bullinger, Kern, &
NIOSH, Waters
et al, Factors,
1993
Braun,
pg.
703 1991
Snook &
Ciriello,
Handbook
of
Human
Factors,
Manual Handling Regulations,Schmidtke
UK Government
TMMK
/ University
Legislation,
1992 of Louisville Study, 2001
TMC
ErgonomicMaximum
Manual, 2001
Recommended
Permissible Weights for
Hand
Wrist Cumulative
Trauma Disorders in
Occasional
Lifts, ILO, 1962
Industry
(Silverstein,Legislation
1986),
Japan Government
on maximum
TMMK/University
of Louisville study 2001).
permissible weights
Handbook of Human Factors, Snook, Vaillancourt,
Ciriello & Webster
Ergonomics, Volume 41, No. 9, M. G. Ricci, 1998
Ergonomics of Manufacturing, M. Helander, 1995
Work Related Musculoskeletal Disorders A Ref.
Book
for to
Prevention,
Kuorinka,
Forcier,Mital,
1995
A Guide
Manual Material
Handling,
TMC
Ergonomic
Manual,
Nicholson,
& Ayoub,
19932001
Hand
Cumulative
SnookWrist
& Ciriello,
1991 Trauma Disorders in
Industry (Silverstein, 1986),
The Ergonomics of Workspaces and Machines,
Corlett & Clark, 1995
TMMK / University of Louisville Study, 2001

TMC Ergonomic Manual, 2001

A
Guide Waters
to Manual
Materials
NIOSH,
et al,
1993 Handling, Second
Edition
Nicholson
Snook &(Mital,
Ciriello,
1991 & Ayoub, 1997),
Handbook
of Human
Factors, Snook,
Vaillancourt,
Manual Handling
Regulations,
UK Government
Ciriello
& Webster
Legislation,
1992
Work
Related
Musculoskeletal
Disorders
A for
Recommended Maximum Permissible Weights
Reference
Prevention,
Kuorinka, Forcier,
OccasionalBook
Lifts, for
ILO,
1962
1995
Japan Government Legislation on maximum
TMMK
/ University
permissible
weightsof Louisville Study, 2001

Explanation
Ergonomic DesignChart
for People at Work (Eastman
Use a push/pull gauge
or load celloftoWeight Frequency
Kodak, 1986),
determine
the initial force
The guidelines have
been developed
upon required
the basis to
of operate.
the NIOSH Lifting Equation (1991) and on the NA
Measure
maximum weight
limit ofshould
15 kg reflect as closely as possible
production
conditions
such as time
required
to lifting frequencies are in the order of 1 lift
The guidelines are
based around
a conveyance
type job
in which
Frequenc
y Guidelines
Lift assist
devices
complete
& lineweights
of forceand lifting height conditions.
every 10
seconds
with various
All figures are based upon a two handed, symmetrical lift with the load le ss than 30 inches across and held close
into the body. Where conditions are likely to deviate from this, a full NIOSH Assessment should be done.

Line 1
Line 2
Line 3

To judge the acceptability of the part under consideration for manual handling:
TMC Ergonomic Manual, 2001
Measured
a push/pull
gauge orthe
load
1) Determine the
height ofusing
the hands
when gripping
part at both
the origin and destination
A Guide to Manual Materials Handling, Second
cell.that falls into the highest number zone (figureEdition
1 below)
determine
the 1997),
rating
2) Use the height
(Mital,to
Nicholson
& Ayoub,
Measure
should
closely
possible
The Ergonomics
scale.
3) Determine
the
frequency
withreflect
whichasthe
part oras
tote
is delivered
per shift. of Workspaces and Machines,
conditions
as time
required to Corlett & Clark, 1995
4) Use Weightproduction
Frequency
chart to such
determine
rating,
Bodyspace, Pheasant, 1998
complete & line of force
MOD 00-25, UK Military Standards
Rear Seat
Exposure Assessment Consensus Document, IEA,
Figure 1
installation
ZONE 3
Weights below Line 3 are rated GREEN

1442mm
(56) panel
Instrument
Interior
garnish
1080mm

(42.5)

Clamp levers
Foot /
880mm
pedals/switches
Start buttons
(35)

Line 2

Weights between Line 3 & Line 2 are rated YELLOW

Weights above Line 2 are rated RED
Ergonomic Manual, 2001
Where forces exceed the other guidelines and TMC
ZONE
Little
& Ferguson2
(1972)
sufficient force, within the time
can Line 2 are rated GREEN
Allconstraints
weights below
only be generated by impact.
Weights between Line 1 and Line 2 are rated YELLOW

ZONE 1

Line
Ergonomics of Workspaces and Machines,
Use a push/pull gauge or load All
cellweights
to
belowThe
Line
1 are1995
rated GREEN
Corlett
& Clark,
determine the force required to operate.
Bodyspace, Pheasant, 1998
Measure should reflect as closely as possible Exposure Assessment Consensus Document, IEA,
production conditions such as time required to 1999
ZONE 2
MOD 00-25, UK Military Standards
complete & line of force
All weights below Fitting
Linethe
2 are
GREEN
Task rated
to the Man,
Grandjean, 1988
Handbook of Human Factors, Bullinger, Kern, &

635mm
(25)

Line 1
NGNG

W1
F1 Weight of individual
+

part (One or two

hands)

Push with thumb

W2
Weight of part,
package or box

(Two hand lift)

F2

Sketch
Sketch

Weights
betweenbyLine 1Braun,
& Line
2 are rated YELLOW
pg. 703
Note: Foot pedal is defined
as operated
TMMK / University of Louisville Study, 2001
movement of the leg with heel unsupported
e.g. vehicles brake pedal.
ZONE 3
Foot switch is defined as operated by
Weights below Line 3 are rated GREEN
movement of the foot with the heel supported.
Weights between Line 3 & Line 2 are rated YELLOW

Weights
2 are rated
RED
HandLine
Wrist Cumulative
Trauma
Disorders in
Gripping &
Measured using a push/pull gauge or
load above
90 100 110 120 130 140 manipulating
150 160 170 cell.
180 190 200 210 220 230 240 250 260 Industry
270 (Silverstein, 1987),
hand tools.
Measure should reflect as closely as possible
4.5kgf
Grip to push/pull production conditions such as time required to
wire harness
complete & line of force
through firewall
80

P arts / Totes delivered per shift

Zone 3Zone 2 Zone 1

Item
Item

Weight Kgs

Meaning of Value

Ergonomic Design Guideline

Should
ShouldNot
Not
Ideal
IdealValue
Value
Typical
Typical
Measurement
MeasurementCriteria
Criteria
References
References
Ideal Value
Measurement Criteria
References
Exceed
Exceed
Exceed
Value
Part/Example
Part/Example
ISO
Silverstein
Toyota
Standard
Process
et5349
al, Assessment
(1998)
(2001) British
procedure
Standard 6842
All
impact
No
red
tools
Vibration
=
Acceptable
Turning
Red
process
and
levels
grip
as
determined
force
are
based
is
generated
by
upon
a
Toyota
by
the
Continued
Repetitive
Identifying
and/or
exposure
and
countermeasuring
high
to
force
vibration
twisting
can
of
Vibration
Hand
Task
elements
fitted
levels
fasteners
designed
can
be
should
acquired
within
be
the
Impact
All
short
wrenches,
Takt
To
Use
measure
a
the
load
appropriate
use
cell
an
to
measure
accelerometer
Toyota
required
Process
attached
grip
JT1
P1
T1
ToolOverall
vibration
ANSI
TMMK/University
S3.34
of Louisville study (2001)
exposure
fingers/hand.
ergonomic
limits
burden
(Typically
set Assessment
out inwhere
ISO 5341
the
Tool
dia.
Hand
of lead
actions
ergonomic
to the
withdisruption
risk
thefactors
fingers
ofreduces
can
the vascular
over
from
designed
force/weight
mosttomanufacturers.
insert
guidelines
with areduce
minimum
Tools of must
cycle based asAssessment
pressure
close toor
the
measure
procedure
handle as
required
possible.
torque
Take
using a Handbook of Human Vibration, Griffin, 1990,
processes
have anti 2.5m/s/s (leq )
Assessment

Less than
3
Less than 3
Arm
the object
Vibration.
is <15 mm). requiring a pinch and
burden
physical
neural
the
burden
systems
smallon
muscles
the
of the
t/m's
of
hands
the and that
force/rotations
burden
carry
values.
a CEand
mark
provide
for export
the to
processes
reading
torque with
wrench.
tool in normal operation for leq
vibration
collars
TMC Ergonomic Guidelines only looks at force, not
Twist
with
Hand started nuts
Score
Measurements
type grip.
can be taken using an
eventual
fingers and
impairment
hands. Contact
referred
stress
to asto the
maximum
Processes
EEC must
possible
set have
up togrip
been
reduce
area.
measured
the
Where
need complete turns complete turns
level.
Measurement
Time operation
conditions
per cycle
should
forreflect
calculating
actual the number of turns
+
or
bolts
Fingers
accelerometer or data obtained from the Secondary
the sides ofRaynauds
the fingersorcan
Vibration
damage
under
bolts
for
reaching
must
stated
beabove
conditions
hand shoulder
started
andthe
the
or pitch
below Ifand/or
< 3kg
and/or < 1kgf
8hr
operating
exposure
conditions.
levels.
measured,
tool manufacturer.
White
small, Finger.
shallow lying nerves and blood levels
of theheight
knee
thread
reported
reduce
should
in theburden
be
tools
suchvalues
that no use vibration =
vessels.
literature.
more than
3 turns
are required.
Body access points, edges and parts
Manipulation
of parts with sharp
Where
possible
design
with a
No sharp
edges
Door access ports
4m/s/s
( leq
)
D1
All Parts &
CumulativeTrauma
TraumaDisorders
Disorders:
A Manual 1988)
for
Cumulative
(Anderson,
Angularbe
should
deviation
designed
is so
measured
as to minimize
from
Because
edges
or
the
working
tendons
in their
of the
close
fingers
Wrist angle
smooth
rounded
can
be
edge
affected
or "roll
byover"
the
for w/Harness
The degree of bend can be visually
Weight
assist
Measured
as
the
total
weight
of
the
tool
Heavy
tools
if
unsupported
place
Engineering
should
either
aim
to
Impact
wrenches
P2
T2
Tool
Body
Panels
Installing
lock andMeasured weight is that of the tool plus

Musculoskeletal
Diseases of Helander,
the Upper 1995
Limbs
Ergonomics
of Manufacturing,
neutral
laceration
wrist
potential
posture.
and
contact stressors
pass through
proximity
creates
athe
laceration
the ability
hazard.
to
work height,
sharp
edges.
accessibility,
handle
installation required
estimated,
measured
indirectly
from
a video
plus
attachments
and
air/power
lines
additional
loadthe
onwrist
operator.
purchase
lightweight
toolstool
or plan
socket
or
attachment
and
hoses
or
if > 2kg
(Putz-Anderson,
(1994)
Design and Selection of Power Tools, Mital &
window

Weight
45 extension
apply force is reduced as the wrist is for
orientation,
and line
of force
still or directly using a goniometer.
Guidelines for designing jobs featuring repetitive
the provision
of assist
devices.
Kilbom
mechanisms into cables.
tasks, R. Bergamasco,
C. Girola
and D.
Colombini,
Ergonomics
Design for People
at Work,
Eastman

50
extension

45
flexion
bent
from
neutral
(mechanical
requirements.
Care
should
be
taken
This
is
especially
important
where
Vital
parts
list
Ergonomic
problems
on
current
mass
Learn
from
experience
and
identify
Use
data/feedback
supplied
by
the
Torsion
bars

the
inner
door.
D2
Historical
(1998)1986,
Wrist
Bend
Kodak,
disadvantage)opportunities
requiring higher
to provide
sufficient
clearances
to
No
75repeat
flexion
10 radial
tools
are used
overhead.
production
improvement
end
users
to begin
design
review
Handle positions
Concerns

muscular effort to complete the task. allow

the wrist to be kept straight
15 ulnar
products must not be
process.
concerns
on manual spot
Increased
pressure
within
the
wrist
is
when
completing
the
operation
carried over to new models. They must
All historical concerns should be
welders
Cumulative Trauma Disorders (Anderson, 1988)
The
total
usable
length
of
the
tools
Where
tool
handles
are
too
short
they
Engineering
should
aim
to
Length
Impact
wrenches, Measured along the usable length of the
a cause of Carpal Tunnel Syndrome. addressed
T3
Tool Handles
be corrected during trial activity.
Ergonomics of Manufacturing, Helander, 1995
Toyota
Process Assessment
Procedure
handle
press
into
the
base
of
the
thumb
and
purchase
satisfactory
tools.
torque
wrenches,
handle.
>115mm
Object
is
held
static
Static
loading
significantly
increases
Eliminate
or
reduce
the
time
that
an
Each
separate
time
a
part
or
tool
is
held
The
Ergonomics
of Workspaces
andMital
Machines,
P3
and Selection
of Power Tools,
&
Both maximum and minimum drawing
Confirm that parts fit forces stay within Relevant fit forces need to be
End of
Garnish
Fit forces should be assessed at the extremesDesign
D3
Parts
La
Depense
Energetique
Length

Corlett
and Clark,
1995 Chez lhomme, Monod
may
cause
Tendonitis
(Dupuytrens
When
building
equipment
requiring
manual
spot
Kilbom
Based
on
criteria
used
for
SJT/JT
muscular
burden
and
where
object
is
held/supported
by
placing
unused
within
a
process
that
exceeds
5
(1967)
dimensions
cause
no
additional
guidelines
at
the
tolerance
limits
established
at
both
ends
of
the
of
proposed
fit
tolerances.
tolerance
parts

Carrying
part to seconds.
Bodyspace,Design
Pheasant,
1998 at Work, Eastman
Ergonomics
for People
Tolerance

Contracture)
handles
dimensions.
welders
Assessments
parts/tools are supported without
closer tospecify
the
point
of use, use of
5OK
secfor
each
ergonomic
burden.
tolerance
range.
Ergonomic
Kodak,
1986,Design for People at Work, Eastman
be fitted later in
being used may increase non value
balancers
etc
Holding Part
pick
holding
&
Kodak,
1986
Bodyspace,
Pheasant,
1988
Consideration should be given to
workability
process rather
MOD 00-25,
UK Military
Standards
added work
Cumulative
Trauma
Disorders
(Anderson, 1988)
Dia.not
30moving
- 50mm
The diameter of the tool handle at the
Handles
that are too small require
Engineering
should aim
to where
Impact
wrenches,
Tool
limiting the tolerance
range
ToolorHandles
than use
dolly or Measure diameter at grip point or calculate
Handbook of
of Manufacturing,
Human Factors,Helander,
Bullinger,1995
Kern, and
Ergonomics
(static)
grip point.
additional force to grip. Oversized
purchase
tools. be met
torque
wrenches,
from
measuring
circumference.
otherwise satisfactory
guidelines cannot
Braun,
pg.
703
Design and Selection of Power Tools, Mital &
return to flowrack
Diameter
Handbook of Human Factors, Schmidtke
handles may cause hyperextension of When building equipment requiring
manual spot
Kilbom
ErgonomicsDesign
Workspace
and Machine
and
for People
at Work, (Corlett
Eastman
Body access points should be designed the
Access
points must be sufficient to
Design consideration
must be given Hand openings
Doorwelders
access ports Measurement to include the usable area of Ergonomics
fingers.
handles
specify dimensions.
D4
Accessibility
Clark,1986,
1995)
Kodak,
Fitting the Task to the Man (Grandjean, 1995),
so
that t/m's
canthe
perform
the surface
requiredto
allow
the required
level
of accessibility
to
the surface
accessibility
needed
to
for w/Harness the
accessfrom
port,the
excluding
irregular

100mm
Measured
from
standing
Surfaces
that
are
too
high
typically
Work
heights,
line
heights
Use
880
Measured
standing
work
surface
to
P4
Ergonomic
Design
for
People
at
Work,
Pg.
71,
Bodyspace,
Pheasant,
(Vehicle/product

Corlett & Clark

The 1988
ergonomics of Workspaces
task
without constrained
postures
i.e.
finger,
arm, otherwise
accomplish
the task, forces
and
installation
edges/incursions
that limit
access.
x100mm or
1 Eastman Kodak, 1983
the principal
working position
of theor
cause
the hand,
t/m's elbows
to be held
should be determined
so that
thetools
the height of the hands
when
performing the Vol.
1080mm
and machines
1995

Cumulative
Trauma
Disorders (Anderson, 1988)
structure
only)
High
friction
The
handle
material
at
the
grip
point.
A
smooth,
polished
handle
surface
Engineering
should
aim
to
Impact
wrenches,
Subjective
measure.
Consider
the
impact
of
becoming
trapped.
contact
stresses
against
the
sides
required
and
the
avoidance
of
poor
similar.
hands.
away from the body causing muscular t/m's hands are within the principal
task.
for principle
Pheasant ofBodyspace
1998Helander, 1995
Tool Handles
Ergonomics
Manufacturing,
will
grip force
satisfactory
tools.
torque wrenches, contaminants and gloves on friction between Design
surface.
McConville
et al Anthropometric
data
of &
U.S.
and/or
postures
maytocause purchase
or
constrained
postures.
Finger
openings
The principal work height refers to the
loadrequire
onawkward
the greater
shoulder.
working
zone
when
performing
the
work ht
and Selection
of Power Tools,
Mital
+
Material
civilian
population
1981
Machinery,
fixed
maintain
Sharp
or the
When
the hand and tool handle.
ridges
Kilbom
injury.
height at which the majority of a cycles
Surfaces hold.
that are
too ridges
low cause
task. building equipment requiring No sharp

60 mm
x
Principal Standing
880mm
to
for equipment & manual spot
workstation
Ergonomics Design for People at Work, Eastman
may
cause pressure
handles specify material.
welders and
work is performed and is based on typical indentations
t/m to stoop or
bend
60mm
TMC Ergonomic
Guideline uses 1100mm
1080mm
develop
Operating Range
Kodak,
1986,
conveyor
heights
points
on
the
finger
flexor
tendons
TMC Ergonomic
Manual,
light to med.
Bodyspace,
Pheasant,
19882001
Zones of
Sensory
Precise
Shift assembly
Feeling type activity
Where there is no sensory perception Clip fit parts are designed with a
Push fit parts Subjective measure of feel and feedback.
D5
Parts fit feeling
to may
Trigger
Finger
Heights
are
elbow
heights
Convenient
T/m
must
bebased
able toupon
detect
by feel
the of leading
of fit t/m's
exert
excessive
sensory feedback mechanism.
Consideration must be given to limitations of
perception of

The Ergonomics of Workspaces and Machines

US
population
& include
a 30mm
The
force
required
to activate
thecorrectly
tool
High
forces
pressure
Single
finger
Impact wrenches, Measure
point
at which
the
connection
is
pressure
or cause
strike the
part topoints
ensureon Engineering should aim to
PPE. using a load cell placed over the
Reach for
fit required
T4 Trigger activation
(Corlett & Clark, 1995),
allowance for work shoes/boots.
the finger
tendons
purchase satisfactory tools.
grinders, manual trigger or push gauge and activate the tool.
> 0.25 & <1kgf,
made.
correctflexor
fit, which
can that
leadmay
to
processes
Ergonomics Design for People at Work, Eastman
force

cause
Trigger
Finger.
When
building
equipment
requiring
spot
welders
2
or
more
Kodak,
injuries
of
the
hand,
wrist,
arm
and
Corlett1986
& Clark The ergonomics of Workspaces
Measured from hip to the knuckles at the Excessive reaching increases the
For processes done on the vehicle
Where
reach
is
limited
only
by
the
position
of
P5
Max<2.5kgf
reach
Bodyspace,
Pheasant,
and machines
1995 1998
low loading
a force on
gives
sensory and triggers
specify
force
fingers
shoulder.
Fitting small parts the t/m e.g. on a Raku seat measure the
farthest point of operation where no edge Too
muscle
theno
shoulders
the designer
must
consider where
Pheasant
Bodyspace
1998
< 700mm
+
Hazardous
Communication
Standard
feedback.
Chemicals
should be chosen to reduce
Least
harmful
materials
should
be
Design
decisions
consider
Minimal
but
Cosmo
into
the Cspray
pillar distance from either the center of the shoulder OSHA
D6
Chemical
OR
back and
increases
the time
required
the
t/m is
situatedmust
to carry
out thethe
McConville et al Anthropometric data of U.S.
1910.1200
[
635mm]
hazards
and
used
where
possible
to
minimize
need
for
and
application
of
materials
used
in
IP
Adequate
civilian
population
1981
from
inside
the
Measured
from
the
belt
buckle
or
front
to
perform
the
job
element.
operation.
joint
or
hip
joint
depending
on
the
height
of
Canadian
WHMIS
Regulations
+
Risk

Max Work
Recommended
Human Performance Ergonomics, Humantech
minimize
PPE
req'd.
The MSDS must be health risks and PPE requirements.
that may
impact health.
operation
PPE
vehicle.
edge of the
surface/machine
When
designing
the work,inotherwise
from
theestablished
edge of the
NIOSH
2003
< 85dBa
Measured
aswork
an 8hr
time weightedto the Where overall levels exceed 85dB;
Where
the sound energy level of a
Measure
accordance
with
Assessment
E1 Reach
Noise
(Horizontal)
reviewed.
E.g. spray application vs.consider
dip or the frequent reach
Loading
pressed
knuckles
at
the
farthest
point
of
operation
machinery/workstations
machine
and
use
numbers
in
brackets
average within the operators hearing
engineering solutions should be
single piece of equipment exceeds
methods (ANSI B11. TR5)
zone
Chemicals
listed
on
the
Environmental
brush
application
parts into a multi

and use bracketed numbers [x].

distance
from the front
edgebeto the
zone.
identified to reduce levels.
82dB
consideration
should
< 450mm
Chemical Banned list not allowed.
welder
farthest
reach.
made
ofrequired
its' impact
to the total level
Frequent reach is > 2 per min.
[ 380mm]
>100mm
Distance between the moving part(s) and Where distances between surfaces
Wherean
possible
Measured at the minimum clearance distance Ergonomics Workspace and Machine (Corlett and
D7
Min. clearance to
within
area. eliminate pinch
Clark, 1995)
Fitting the Task to the Man (Grandjean, 1995),
any
fixed surfaces
which
create a to
pinch that
are
moving
together
canefficiently
be made points
and
potentially
the need for
between
the required
convergent
surfaces.
Workstations
should
be
designed
T/m's
are
able
to
work
more
Where
reasonably
practicable
To calculate
accommodation
use
Adjustable
European Standards EN349 1993 Safety of
P6
prevent pinch points
Corlett & Clark The ergonomics of Workspaces
Accommodate
point
>100mm,
the
pinch
point
hazard
for
guarding
by
creating
adequate
IES
Machinery,
standards
accommodate
all
height
ranges
and
and
with
reduced
risk
of
injury
if
the
working
heights
should
anthropometrical
tables
for
relevant
Measured at the worksurface or point
Ensure that there is sufficient light to Consideration must be given to the
Refer to IES
Accommodates
Measured using a light meter (photometer)
platforms.
and machines 1995
E2
Process

for T/M
hands
&
wrist
height variation
ISO 13854
the
hand
or
wrist
is
eliminated
and
clearance
distances
include
adjustability
where
required.
tasks
can
be
accomplished
within
accommodate
a
range
from
a
5th
population.
Pheasant Bodyspace 1998
Height
where work is done.
complete task without straining eyes type of work being done and the
Std for type
5th %'tile
Temporary positioned at the work position.
equipment
where
(for moving
McConville et al Anthropometric data of U.S.
Lighting
may
not
require
guarding
where
their
zone
ofposture
convenient
reach.
%'tile female
95th
%'tile male
or
adjusting
to accommodate.
required
light to
level
together
with the
of work
female &
wooden or
Variation
civilian population 1981
if not
guarded)
reasonably
further intrusion into the working zone direction
either as and
a fixed
height
or with
a
quality
of light.
E.g.
(Table 2)
95th %'tile male Styrofoam floor
practicable
is prevented.
sufficient
range
of
adjustment.
Color rendition
tiles
Workspace and Machine (Corlett and
Distance between the moving part(s) and Where distances between surfaces
Where possible eliminate pinch
>25mm
Measured at the minimum clearance distance Ergonomics
D8
Min.
clearance
to
Pheasant
Bodyspace 1998
Measured
from
the
standing
surface
to
Excessive
stretching
and
overhead
This
height
ensures
that
all
US
t/m's
Measured from the standing work surface to Clark,
1995)
P7
any fixed surfaces which create a pinch that are moving together can be made points and potentially the need for
between the convergent surfaces.
McConville
et al Anthropometric
of of
U.S.
European
Standards
EN349 1993 data
Safety
TABLE
prevent
2
pinch
points
Notes:the
knuckle
of
the
hand
gripping
the
reaches
place
increased
loading
on
will
be
able
to
reach
&
grip
an
the
height
of
the
hands
when
performing
the

civilian
population 1981
point
>25mm, the pinch point hazard for
guarding by creating adequate
Machinery,
IES Recommended
for Automotive
When designing a lighting
environment
consideration
overall level. In areas where color differentiation
is required a light source with a
object. Manufacturing and Assembly Facilities
the body.
overhead
object. Care
should be needs to be given to direction and quality of the light as well asoperation.
for fingerIlluminance Levels1820mm
ISO 13854
fingers is eliminated and may not
clearance distances
Max Work
Color Rendering
Index
(CRI)where
of 86 this
is recommended.
developed on the functional grasp Inability to reach a required
tool or
exercised
may impact
Suspended Tools
(for moving
equipment
< 1820mm
ACTIVITY Criteria
ILLUMINANCE
require guarding where further
of a 1%'tile female plus 30mm for work
control may impact a t/m's ability to
head clearance for taller t/m's
Control panels
Reach
(vertical)
if not guarded)
into the working zone is
Exterior
inactive
storage, railroad switching, outdoor
substations, parking areas
1.5intrusion
fc / 15 lux
For general assembly and manufacturing a CRI of >80 is recommended with a recommended minimum of 75.
shoes/boots.
perform
a task.
prevented.
NB This height is below head height for
interior storage area, exterior pedestrian entrances
and truckthe moving part(s) and5 Where
fc / 50 lux
>500mm
Distance
between
distances between
surfaces
Where
possible
pinchon an individual
at the minimum
distancefor.Ergonomics Workspace and Machine (Corlett and
D9Inactive
Min.
clearance
to
Lighting
for inspection
areas
shouldeliminate
be assessed
basis depending on the type of articles or surfacesMeasured
being inspected
and whatclearance
is being checked
approx
25%
of Male population
Clark, 1995)
maneuvering areas
any fixed surfaces which create a pinch that are moving together can be made points and potentially the need for
between the convergent surfaces.
Revised NIOSH
Equation
(Waters
et al., 1993)
European
Standards
EN349
1993 Safety
of
prevent
pinch
points
Theactive
upperstorage
limit is measured
from the floor
handling above
When planning parts storage
Stores and line Upper limit; measure from the standing
Elevators,
P8
steel
furnace
areas, locker rooms, exterior
areas.
20 Manual
fc / 200 material
luxthe pinch
Max top shelf
point
>500mm,
point hazard for
guarding by creating adequate
Snook & Ciriello 1991
to the shelf. The height of the lowest shelf shoulder heights is a major cause of requirements sufficient room needs
side flowracks surface to the surface of the upper shelf. The Machinery,
for
torso
(for
moving
Manual
Handling
Regulations
1992

UK
ISO
13854
Waste
treatment
facilities
(interior),
casting
furnace
area,
HVAC
and
substation
30
fc
/
300
lux
1500mm
the body is eliminated and may not
clearance distances

is determined by the height of the hands injuries.

to be allowed to keep shelf heights
limit is set to allow the shelf height plus one
Government Legislation
equipment
not guarded)
rooms,
loadingifdocks,
toilets and washrooms
Advisory lowest
require guarding.
Flowrack/ paint mix rooms, steel stores,
when picking.
Repetitive handling of loads below
below 1500mm,and ideally above
box and assumes gripping at the base of the Pheasant Bodyspace 1998
height
of
635mm
General assembly, welding, stamping, painting, active
storage
areas
50
fc
/
500
lux
Distance
between
the moving
and 800mm
Where distances
between surfaces
Where possible
eliminate
pinch and
>180mm
Measured at the minimum clearance distance Ergonomics Workspace and Machine (Corlett and
D10 Parts
Min. clearance
to
NB
This criteria
should
be usedpart(s)
in
requires bending/stooping.
635mm
(knee height)
for storage
object.
height
Clark, 1995)
Min height for
Machining,storage
large casting
core and molding areas, control
and
dispatch
rooms
75
fc
/
750
lux
any
fixed
surfaces
which
create
a
pinch
that
are
moving
together
can
be
made
points
and
potentially
the
need
for
between
convergent
surfaces.
conjunction with W2 when considering
above 800mm for parts used each
The lowerthe
limit
is measured
to the position of European Standards EN349 1993 Safety of
prevent pinch points
parts used each
point
>180mm,
the
pinch
point
hazard
for
guarding
by
creating
adequate
layouts
Takt cycle.
the knuckles when gripping the object, This is Machinery,
for leg
Takt cycle 800mm
Small component
assembly, medium casting core and molding areas, grinding
100 the
fc / 1000
ISO 13854
leg is lux
eliminated and may not
clearance distances
done to reflect the impact of object height.
(for moving
equipment
and chipping,
ordinary
inspection, maintenance and machine repair areas,
require guarding where further
Human Dimension and Interior Space: A Source
All clearance dimensions are based upon To ensure that there is enough
For equipment design access points
Head clearance
Access widths are measured at shoulder
P9polishingifand
not burnishing.
guarded)
intrusion into the working zone is
Book of Design Reference Standards (Panero and
a 95th %'tile male wearing industrial 150 clearance
for t/m's to be able to do
into machinery.
1915mm.
height.
Zelnik, 1979),
Parts
inspection
stations
fc
/
1500
lux
prevented.

clothing/PPE.
work and limit constrained or awkward Layout of equipment and processes.
Access width
Positioning of
Bodyspace: Anthropometry, Ergonomics and
Ergonomics
Workspace
and1991)
Machine (Corlett and
Final
assembly,
body
finishing,
fine
inspection,
paint
color
comparison
200
fc
/
2000
lux
>120mm
Distance
between
the
moving
part(s)
and
Where
distances
between
surfaces
Where
possible
eliminate
pinch
Measured
at
the
minimum
clearance
distance
Design of Work
(Pheasant,
D11 Min.Machinery
clearance to
postures.
650mm,
machinery in a
Clark, 1995)
Human
Factors Design Handbook (Woodson et al,
any
fixed
surfaces
which
create
a
pinch
that
are
moving
together
can
be
made
points
and
potentially
the
need
for
between
the
convergent
surfaces.
Fine,
difficult
inspection
(casting
cracks)
500
fc
/
5000
lux
For
vehicle/parts
design
where
900mm
if
carrying
process
to
allow
European
Standards
EN349
1993 Safety of
Accessibility
pinch points
1992)
prevent
point
>120mm, the pinch point hazard for
guarding
by creating
adequate
Machinery,
access ports
are required
to
a load >750mm.
adequate access
Ergonomic Design for People at Work (Eastman
for feet
ISO
13854
the foot is eliminated and may not
clearance
distances
Kodak,
1983),
complete tasks
see D4
Hand access
(for moving equipment
require guarding where further
110mm x 110mm.
if not guarded)
intrusion into the working zone is
prevented.

Item

TOOLS
DESIGN OF PARTS/PRODUCT/EQUIPMENT
ENVIRONMENT

POSTURES

Sketch

Criteria

Purpose

Design
Design Application
Application

Ergonomic Design Guideline