GE75 021R English

RENAULT 2002 Origin: PEGI Renault Page: 1 / 55
Guide of help of the Ergonomics of

industrial machines and installations
GE75-021R /B
________________________________________
Guide
________________________________________
Status Executory

Important Note : This document has been translated from the French. In the event of any dispute, only the French
version is referred to as the reference text and is binding on the parties.

Object ! To help designers to interpret exactly the texts of the European directives and the
existing norms in the field of ergonomics.
! To capitalise the satisfactory solutions.
! To list the main international, European and French norms to be respected in the field
of ergonomics.
This document will be periodically updated under the responsibility of Department 0814,
according to the significance of regulatory, normative or technical developments.
The present document is not contractual between Renault and its
suppliers.

Application field All Renault Automobiles sites in the world

Issued by 0814 - Working Conditions Department

Confidentiality Not confidential

Approved by Function Signature Application date
M Ferchal Head of Department 0814 03/2002
GE75-021R /B


Version record
Version Update Subject of important modifications Editor
A 10/2000 Creation (1) M. Sailly 0814
B 03/2002 Update of sheets 35 and 36
Update of the ergonomic analysis sheet (Pages 85 to 90)
M. Sailly 0814

Replaces

Made available
Internally on Intranet: http://gdxpegi.ava.tcr.renault.fr
Externally on Internet: www.cnomo.com
E-mail: norminfo.moyens@renault.com

Documents quoted Regulation :
International : ISO 10075-2, ISO 7730.
European : EN 1837, EN 294, EN 547-1, EN 547-2, EN 563, EN 60073, EN
60447, EN 61310-1, EN 614-1, EN 894-1, EN 894-2..
French : NF X 35-103, NF X 35-104..
CNOMO :
Renault : EB75.81.325, EB75.82.125.
Other internal docs : Renault ergonomic analysis method.
Other external docs : ND 2052.

Codification ICS: 13.110; 13.180; 17.140.20

Class E75

Key words Scurit des machines, prvention des risques, ergonomie, machine safety, accident
prevention, ergonomics

Language English

(1) Have collaborated in writing this document
Service Name Service Name
09441 M. Brochard 00845 M. Peron
09645 M. Boulary 09552 M. Renoux
65911 M. Decoster RVI Mme Richard
STA M. Dourlens 66050 M. Tabarly
FASA M. Gonzalez 65912 M. Vernhet
09346 Mme Goubin
09342 Mme Le Prvost
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Summary
Page
1 Presentation of the document ........................................................................................................... 4
2 Glossary ............................................................................................................................................. 4
3 Design procedure............................................................................................................................... 4
4 General design................................................................................................................................... 5
F1 - Implantation and design of means and equipment............................................................................. 6
F2 - Access to work stations and places of work....................................................................................... 8
F3 - Isolated work station ........................................................................................................................... 9
F4 - Signalling measures and service components ................................................................................. 10
F5 - Functional dimensions of equipment ................................................................................................ 11
F6 - Protective equipment ........................................................................................................................ 12
F7 - Documentation.................................................................................................................................. 13
F8 - Noise................................................................................................................................................. 14
F9 - Lighting.............................................................................................................................................. 15
F10 - Thermal atmospheres..................................................................................................................... 17
F11 - Cleaning work stations.................................................................................................................... 18
F12 - Operating installations - Relevance of information......................................................................... 19
F13 - Operating installations - Right-handed and left-handed operators................................................. 21
F14 - Operating installations - Layout of control system components..................................................... 22
F15 - Operating installations - Colours of signalling and control measures ........................................... 23
F16 - Operating installations - Respect of conventions ........................................................................... 24
F17 - Operating installations - Choice of display measures .................................................................... 26
F18 - Operating installations - Analogue display ..................................................................................... 27
F19 - Operating installations - Choice of signals ..................................................................................... 28
F20 - Loading and unloading parts - Tempo of the operator ................................................................... 29
F21 - Loading and unloading parts - Postures......................................................................................... 30
F22 - Loading and unloading parts - Gripping parts ................................................................................ 31
F23 - Loading and unloading parts - Handling efforts.............................................................................. 32
F24 - Controlling the parts - Information and means ............................................................................... 33
F25 - Controlling the parts - Postures, gripping, efforts ........................................................................... 34
F26 - Changing tools and equipment - Information.................................................................................. 46
F27 - Changing tools and equipment - Postures, gripping, efforts .......................................................... 37
F28 - Changing tools and equipment - Openings and access holes ....................................................... 39
F29 - Maintenance or settings - Executing a function.............................................................................. 40
F30 - Maintenance or settings - Spaces, openings and access holes .................................................... 41
F31 - Maintenance or settings - Efforts.................................................................................................... 42
F32 - Supply and evacuation of consumables and waste - Postures and efforts................................... 43
F33 - Repetitive assembly operations - Diversity and complexity ........................................................... 44
F34 - Repetitive assembly operations - Regulation ................................................................................. 46
F35 - Repetitive assembly operations - Postures .................................................................................... 47
F36 - Repetitive assembly operations - Efforts ........................................................................................ 48
5 List of documents cited ................................................................................................................... 49
Appendix 1: ergonomic analysis sheet .............................................................................................. 50
GE75-021R /B

1 Presentation of the document
This guide consists of sheets containing the following themes:
" the rules to respect, reported in the "ergonomics" conformity statement of Renault norm
EB75.82.125 .
" the normative specifications,
" listing the normative documents which can act as a reference,
" extracting the main information from these documents,
" recommendations resulting from the Renault know-how and experience in this field.
Although they provide tried and tested solutions, these Renault comments should not prevent
the provision of more efficient, more simple and/or less costly solutions perfected by the
suppliers
2 Glossary
The following definitions are taken from the European norms.
Work activity: any activity effected by the operator in order to achieve the objectives of the work
system.
Signalling measure: information presentation measure which transmits visual, audible or tactile signals
to an operator.
Work means: tools, machines, vehicles, apparatus, furnishings, installations and equipment used in the
work system.
Operator: the person (people) responsible for operating, tuning, servicing, cleaning or repairing a
machine.
Work component: part of the control system which responds directly to an action of the operator, for
example to pressure exercised by the latter.
Work station: for a given operator, the combination of work equipment in a work space surrounded by
the working environment constitutes the work station for this operator.
Work system: the work system consists of the person and work means, acting together in the work
process in order to effect a task, within the work area in the work environment,
according to the completion conditions for the task to be effected.
Task: activity(ies) necessary to obtain the result set by the system.
3 Design procedure
Normative specifications: EN 614-1 5

The design process can be seen to proceed in 4 main stages (see table below).
At Renault, these stages correspond to:
" the milestone phases of the projects,
" the corresponding socio-technical milestone phases for anything concerning ergonomics.

Design process
(EN 614-1)
Project milestones
Socio-technical milestones
(ergonomics)
Phase 1 : Elaboration and
clarification of specifications.
1. Explanatory and preparatory
phases (milestone: pre-contract).
1. Ergonomic studies of existing
elements. Proposal of
objectives.
Phase 2 : Preparation of design
plan(s).
2. Envelope study (milestone:
contract).
Elaboration of ergonomic
objectives.
Phase 3 : Preparation of detailed
design.
3. Detailed study. 3. Detailed study.
Phase 4 : Implementation.
4. Installation and start-up. 4. Reception, improvements.

GE75-021R /B


Norm EN 614-1 specifies certain points concerning the process of taking ergonomics into account

Phase 1
Define the organisational
objectives
! The design of work equipment should follow the setting of
organisational objectives relating to the work process and the work
equipment should constitute an integral part of the work process.
Identify the characteristics
of the operators.
" The demands of the operator should be specified at this first stage:
identify the specific characteristics of the operators who use the
equipment.
Phase 2

Effect an analysis of future
work.

Involve the future users of
the equipment.
" The initial specifications of the operators' demands should take into
account:
" the results of the analysis of operators' activity on the machines
to be modified or, in the case of new machines, on similar
machines,
" the distribution of functions between the work equipment and the
operators,
" the tasks which the operators will have to execute using the work
equipment,
" the interactions between the operators and the work equipment.
" The users have an important role to play from this stage onwards.

" When the demands imposed on the operator are outside the
acceptable ergonomic levels, the design plan should be reviewed.
Phase 3
Take into account
ergonomic principles and
social and organisational
factors.
" For the detailed design to represent the best compromise between
the technical study and the demands of the operator, reference
must be made to ergonomic principles. Other factors must also be
taken into account, such as work satisfaction and organisational
questions.
Effect work analyses for the
design of interfaces.
" To better design the interface between the operator and the work
equipment, task analyses should be effected, to determine what is
expected of the operator and to take decisions regarding the
information to be supplied to the operators.

" The detailed design should be subject to successive improvements
until the definitive solution can be expressed in the form of detailed
specifications.
Compile the documentation.
" When the design solution has been decided, the documentation
must be compiled, for example: maintenance manual, user
instructions.
Phase 4
Validate with future users
" It is recommended that:
" the equipment be subjected to user tests,
" the documentation be evaluated with them.

4 Rules of conception bound to the ergonomics
See following pages
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F1 - Implantation and design of means and equipment

The implantation and general design are consistent with the methods of use. They allow:
" the following activities to be effected, strictly limiting the machines down-times :
loading and unloading parts, controlling the parts, changing tools and equipment,
maintenance and settings, supply and evacuation of consumables and wastes.
" the execution of the task to be optimised, limiting movement and ensuring good
visibility of the installation.

Normative specifications
EN 614-1 ( 4)
Respect of ergonomic principles applies not only to the intended use of the work equipment but also its
installation, setting, maintenance, cleaning, repair and transport.
The design is essentially focused on the interaction between the operator and the work equipment and
consequently the distribution of the functions and actions between the operator and the work equipment.
The objective pursued consists in designing a work system adapted to human possibilities, limits and needs.
As a result, the design process should integrate a task analysis.

EN 614-1 ( 5)
The design of the work equipment should follow the setting of the organisational objectives relating to the work
process.
The initial specifications of the operators' demands should take into account the following elements:
! the results of the analysis of operators' activity on the machines to be redesigned or, in the case of new
machines, on similar machines,
! the distribution of functions between the work equipment and the operators,
! the tasks which the operators will have to execute using the work equipment,
! the interactions between the operators and the work equipment.

Recommendations

Principles to be respected
! The implantation and design of means or elements of the equipment should be consistent with the operating
and user modes.
! Movements must be as short and untiring as possible.
! Visibility should be at a maximum for the main elements to be monitored.

Elements to be understood
In order to respect these principles, the following points should be closely examined:
! the nature and places of work of the operators (surveillance, control, loading, maintenance, etc.),
! the location of the manual work stations,
! the location of the person-machine interfaces (console, screens, etc.),
! the location of the control station(s),
! the location of the loading and unloading stations,
! the types of defective operating run modes and the localisation of possible discharging and re-stuffings,
! the number, location and types of access to the installation,
! the types of material safety protections,
! the different types of flows (parts, equipment, consumables, etc.),
! the parts-in-progress at the start and end of the line and between the machines,
! the supply and evacuation of consumables and waste,
! the sources of noise,
! the means of extracting the smoke, dust and toxic substances, and salvaging pollutant products,
! pathways,
! areas for communication, meetings, etc.

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Specific recommendations for the passages
! Determine the main sites of intervention,
! Specify the reasons or conditions for passage above the conveyor belts, for all users (drivers, maintenance
professionals, etc.),
! Avoid differences in level.

Specific recommendations for the positioning of control stations
When the control time is long (several minutes):
! place the control station as close as possible to the command station,
! ensure that the operator can monitor the installation and has access to the important information on the
functioning of the installation.

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F2 - Access to work stations and places of work

The access to the work stations or places of work are of the correct size, including for
breakdown assistance and maintenance.


EN 547-1 (3)

The passage takes into account:
! the type of clothing (light or thick) and the protective equipment,
! the transport of tools, for example for maintenance or repair,
! the postures and gestures,
! the frequency and duration of the task,
! the length of passage,
! the level of risk and the space for rapid movement in an emergency,
! the surrounding conditions (darkness, heat, humidity, noise, etc.).

Recommendations

The norm suggests a formula including the elements to be taken into account. As an example, the following
minimum dimensions respect the principles of the norm for:
! a tall man in the 95
th
centile (see sheet no. 38),
! the wearing of ordinary work clothes,
! a straight posture,
! an open space for the movement of the body.

Minimum width of access in mm

Frequent access + people passing 800
Frequent access 715
Secondary access (breakdown, maintenance) 615
Rare access (passage in profile) 545

Minimum height of access in mm

Passage for moving upright 2 070

The implantation diagrams should integrate as soon as possible:
! the safety distances in relation to moving elements,
! the types of protection (height, sizes of mesh),
! the passages of ground conveyor belts,
! the passages of aerial conveyor belts,
! aerial walkways,
! the passages of cables and piping.

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F3 - Isolated work station

There is no isolated operator due to the implantation and/or organisation of the work.

There are no norms dealing with this situation, but there is a documentary note from the National Institute of
Research and Safety in France.
"a task or a work station is to be considered as isolated when the operator is out of sight or hearing of the
others, in most cases for periods of more than one hour. However, for work where the risks could not be
eliminated, the notion of an isolated work station can be understood for periods of only a few minutes." (nd
2052-167-97, 'cahier des notes documentaires no. 167', 2nd quarter 1997 of the INRS)

Recommendations

The situation of isolation should be considered from three angles:
! the mental load work and of anxiety which may occur as a result of not being able to talk or not being able to
confront work situations (doubts with regard to quality, for example) with other colleagues,
! insertion in the work group,
! safety, in particular the risk of not being able to provide assist device quickly.

For each situation of operator isolation, it is recommended that the following procedure be implemented:
! Undertake a study of the problems and risks.
! Take compensatory organisational measures (rotation of operators, etc.).
! Provide all useful information concerning the correct work procedures.
! Provide the operator with the appropriate equipment
! Ensure that the person can be given rapid assist device in the event of manifest residual risks
.

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F4 - Signalling measures and service components

" The important signalling measures are placed in the operator's field of vision.
" The positioning of service components allows movements to be optimised and risk
taking or accidental manoeuvres to be avoided.


EN 894-1 ( 4.3.3)

It is recommended that the body movements necessary to activate the service components are not a source of
interference for the operator.
For efficient running, the different service components must be separated by an optimum distance, as too great
a distance can necessitate pointless movements while too short a distance increases the risk of accidental
manoeuvres.
In order to determine the optimum distance, it is essential that the specific characteristics of both each service
component and the general context of the use be taken into account.

Recommendations

! Describe as early as possible the future activity of the operator.
! Position the command system so that the operator has a view of the entire installation from this station.
! Orient the consoles so that the operator can see the component he is controlling.
! Design the part conveyor belts using swivelling parts or lifts to facilitate access to the consoles.
! Provide for sitting stations as soon as an activity takes place for several minutes without movement.

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F5 - Functional dimensions of equipment

The functional dimensions of the equipment integrate the differences in size and
corpulence of the operators.


EN 614-1 ( 4.1.1)

The design of the work equipment should respect the following principles:
! the height of use or other functional dimensions of the equipment should be adapted to the operator and the
type of work effected, for example by being adjustable,
! sufficient space should be provided for all parts of the body so as to allow the movements necessary to carry
out the task and to facilitate access and changes in the posture.

Recommendations

The design of the work stations is a compromise resulting from:
! an examination of the problems encountered by tall and short people,
! the choice of the least disadvantageous dimensions: with the same back posture, the lower position must
often be favoured.

When the compromise is difficult to determine, the possibility will be examined of integrating dimensional
adjustments on the station which are easy to implement (quick and little effort), ensuring that the installations
are not rendered more complex and the reliability is not affected.

For the dimensions of the equipment, three pieces of anthropometric data must be systematically taken into
account:
! the height of the eyes, which will determine the upper height for taking visual information,
! the height of the shoulders, which will determine the upper limit for access to a technical device or for lifting
an object,
! the height of the hands (with arms at side of body), which will determine the lower limit for access to a
technical device or for lifting an object.

See the French norm NF X 35-104 concerning dimensions for the design of work surfaces and volumes.

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F6 - Protective equipment

The design of means includes material protection measures and individual protective
equipment.


EN 614-1 ( 4.1.1)

No specification

Recommendations
1. Material measures
Norm EN 294 sets the safety distances to prevent dangerous zones from being reached by the upper limbs.
In order to respect the ergonomic recommendations, the best compromise possible is required between safety
and visibility of the installations. For the protective grilles, this implies:
! choosing the largest possible authorised mesh,
! maintaining good visibility above the protection, respecting the heights specified in the norms,
! having a dark matt colour to facilitate visibility through the mesh,
! choosing square or rectangular meshing (left-hand photo) without rippled wire,
! providing either a plinth to avoid entry of dirt, or a gap of 200 to 250 mm between the ground and the
protection to facilitate cleaning (using a brush).

2. Individual protective equipment

Adopt the following procedure to limit the risks and adapt the means of protection to the work activity:

! reduce the risks at source through the design of the product and the design of the product-process,
! in the event of risk, favour collective protective measures,
! if a risk remains, adapt the individual protection to the activity, avoiding the operator having to put on and
take off the protections very frequently.
! specify the type of individual protection marked on the safety sheet at the work station.

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F7 - Documentation

The documentation on the use and maintenance of the equipment is available and
understandable to the users.


EN 614-1 ( 5.2.3)

The documentation should include the operator information and the method of using the equipment
ergonomically.

Recommendations
The preparation of the documentation should occur in four stages:
! the definition of the functioning modes,
! the associated definition of the user modes, which can lead to the adaptation of certain functioning modes,
! the preparation of an operator manual or notebook,
! the preparation of safety sheets (precautions to be taken, wearing of individual protections, etc.) and
instructions for use of chemical products or dangerous substances.

The preparation of the manual or notebook should be effected by:
! referring to the supplier documentation,
! involving the future operators,
! by capitalising the know-how transmitted within the framework of supplier training courses,
! by differentiating the information for learning periods (operating procedures, etc.) from the information for
experienced operators (resolution of complex problems, etc.).

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F8 - Noise

" The noise levels are below the following values:
" 75 dB(A) for equipment in the assembly sectors,
" 80 dB(A) for equipment in the other sectors.
" The peak level is below 130 dB (C).


EN 614-1 ( 4.4.1)
The noise emissions and vibrations produced while the work equipment if functioning should be reduced to the
minimum in order to avoid health risks and to ensure the comfort of the operators.

The design methods should allow the emissions to be controlled at source to an extent that the final emission
values are low compared to the other machines of the same type.

EB75.81.325
Apart from particular specifications during the call to tender, the limits not to be exceeded at the station and at
any point located within one metre of the equipment are as follows:

Workshops LpAeqT Lpc
Pressing, forge, foundry, stamping, boilerworks.
Machining, bodywork, framing, painting, plastics.
80 dB(A) 130 dB(C)
Fitting, assembly, upholstery, body trimming. 75 dB(A)

The number of measuring points is equal to the perimeter of the work equipment (in metres) divided by 5, with a
minimum of 4 measuring points.

Measurements are taken 1 metre from the work equipment and at a height of 1.60 m.

The clearly identified work stations are also measured at the height of the operators' ears.

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F9 - Lighting

" Lighting is adapted to the task to be effected. It is at a level of between 500 lux for
work on average-sized parts and 750 lux for work on small parts.
" There is no dazzling.
" The rendering of the colours is satisfactory.

EN 614-1 ( 4.4.3)
When the analysis of the task emphasises insufficient ambient light, integrated lighting should be provided, for
example for adjustments to be effected.
This lighting should be designed so that the operator does not have to adopt an uncomfortable posture.
When the lighting must be adjusted, the means of adjustment must be situated in an appropriate location and
should avoid placing the operator in danger.
Particular attention should be paid to the following points:
! avoid any twinkling of the lights,
! avoid all dazzling lighting,
! avoid the projection of shadows which are likely to create a certain confusion,
! avoid stroboscopic effects,
! lighting contrasts should be sufficient for the task to be effected,
! the rendering of the colours must be maintained.

EN 1837 ( 4.2 to 4.5)
The lighting required depends on the visual task and must be sufficiently bright and uniform to allow sure and
comfortable visibility of the details of the visual task.
As a general rule, an average maintained lighting of at least 500 lux must be accompanied by a minimum
uniformity (E
min
/E
average
) of 0.7 in the work zone and 0.3 for the immediate surroundings of the task.
The integrated lighting system must avoid dazzling... and be designed and adjusted to avoid interfering
shadows...
The properties of the rendering of the colours and the visible colour of the lights must be chosen to allow good
distinction of the colours of the visual task and the comfort of the user.

Recommendations

The following elements are taken from the norm NF X 35-103 and the recommendations of the Lighting
Association.

Average recommended lighting levels

Applications lux
Entrances, yards, alleys
Covered traffic lanes
Docks and quays
30
50
75
Corridors, stairwells
Warehouses
100 to 300
125 to 150
Offices, typing areas
Drawing rooms
425 to 500
1000
Machines-tools, workbenches, welding
Work on average-sized parts
Work on small parts
Fitting of small parts
250 to 300
425 to 500
625 to 750
625 to 750
Very intricate work or very small parts 1250 to 2000

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Temperature of colour and colour rendering index

Applications Lights Temperature of colour
in Kelvins (K)
Colour rendering
index (IRC)
Regular workshops
Administrative offices
White rooms
Fluorescent tubes
2700 to 6500

! 80
Industrial halls and premises
of a height of more than 8 m
Iodides

Mercury vapour
3700 to 6100

3300 to 4300
65 to 93

33 to 60
Very high premises,
warehousing, hangars
High-pressure
sodium

2000 to 2500

25 to 80

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F10 - Thermal atmospheres

" In the periods when heating is used and for a regular industrial activity, the
temperature lies between 16 and 22, with relative humidity between 30 and 70 %.
" There are no draughts, verified by an air speed which is, in principle, less than 0.25
m/s.

Warning, this sheet does not deal with conditions of extreme heat at work (thermal treatment, foundries, etc.).

EN 614-1 ( 4.4.2)
The thermal emissions produced while the work equipment is functioning should be reduced to the minimum by
means of the design methods in order to avoid health risks and to ensure the comfort of the operators.
! the physical load of the operator,
! the thermal properties of the required clothing,
! the foreseeable thermal load for the operator,
! the temperature of the tangible areas (see EN 563)

ISO 7730
Thermal comfort is defined as the satisfaction expressed with regard to the thermal atmosphere.
Dissatisfaction can be caused by:
! tepid or cool discomfort for the body, etc.
! a draught...
! abnormally large differences in temperature between the head and the ankles.
It is impossible to stipulate a thermal atmosphere which satisfies everyone. However, it is possible to stipulate
atmospheres which are acceptable to a percentage of the occupants.
According to appendix C of the norm, and in order to satisfy at least 93% of the occupants, the operating
temperature should correspond to the following values for regular industrial activity (metabolism of 116 W/m
2
).

Operating temperature Clothing
Other characteristics of
thermal atmosphere
16 to 19
Underwear, shirt, trousers, socks, shoes.
Relative humidity of 50%
19 to 22
Boxer shorts, short-sleeved shirt,
lightweight trousers, thin socks, shoes. Air speed of 0.15m/s

According to appendix B of the norm, the following values are given for the metabolism per profession:
- intricate mechanics 70 to 110 W/m
2
.
- welding and turning 75 to 125 W/m
2
.
The operating temperature can be calculated, with sufficient approximation, as the average value of the air
temperature and the average radiation temperature.

GE75-021R /B


F11 - Cleaning work stations

If dangerous materials are used, appropriate measures are available to avoid the
operators being exposed to health risks.


EN 614-1 ( 4.4.4)
The work equipment must be designed so that any dangerous material and any dangerous radiation present
during use are indicated and dealt with via appropriate measures in order to avoid the operator being exposed
to health risks.

Recommendations

The use of dangerous substances and products is limited to those that are strictly necessary, favouring the least
dangerous, and requires permission for use. The suppliers, in particular, are bound to communicate to the
company the composition of the products so as to adapt the protective measures accordingly.

The products used:
! are labelled according to the regulatory criteria,
! are packaged, stored, handled, used and eliminated in a way which reduces the risks,
! are provided with user instructions indicating the rules of use to be respected and the obligatory individual
protections to be worn.

Any emission of dust, steam or smoke must be collected at source, according to the following principles:
! provide maximum cover of the zone where the pollutants are produced,
! collect them as close to the emission zone as possible,
! position the extraction device so that the operator is not situated between it and the pollution source,
! use the natural movements of the pollutants,
! induce a sufficient air speed,
! distribute the air speeds uniformly at the level of the collection zone,
! balance the air outlets by corresponding air inlets,
! avoid draughts and feelings of thermal discomfort,
! eject the polluted air outside the clean air inlet zones.

Protection against radiation is dealt with within the framework of the safety conformity report.

GE75-021R /B


F12 - Operating installations - Relevance of information

" The signalling devices provide clear and unequivocal information.
" The information important to the efficiency of the process, safety, security and the
reliability of the system are obtained via different means.
" The control system is adapted to the learning and individualisation possibilities:
" a possible adjustment of the information needs,
" a possible choice between simplified and detailed procedures for the access to
information or parameter control (e.g. adaptive menu).


EN 614-1 ( 4.3.1)
The signalling means should be designed, chosen and arranged to be compatible with the characteristics of
human perception and with the task to be effected.
! the signalling means should be designed so as to be understood clearly and unequivocally; this is
particularly important for emergency displays and signs,
! in order to avoid an excess of information, the number and type of displays and signs should be limited to
the minimum required for the correct execution of the task,
! the presentation of unnecessary information should be avoided,
! the signalling means should be positioned in such a way as to favour a sure, clear and rapid orientation and
recognition.

EN 894-1 ( 4.3.1)
In certain situations, the efficiency and security of a system depend on its ability to present repeated information
to the operator. It is recommended that important information be able to be obtained from different sources.

EN 894-1 ( 4.6)
The system should be sufficiently flexible to be adapted to the different individual needs, general physiological
and psychological capacities and learning capacities, as well as cultural differences.
The operator should, if possible, be able to modulate the speed of interaction. An experienced operator should
be capable of structuring the feedback information for it to correspond to his level of competencies. Inversely, it
is recommended that an inexperienced operator be able to adjust the level of the feedback information to his
needs.
In a complex system, it is desirable that the operator have a choice of an availability of global or detailed
information concerning the system.

Recommendations
Five categories of information can be contained in a user assist device system:
! operating aids (changing tools, restoration of the cycle, changes in working modes, monitoring of drifts,
information on induced stoppages),
! production management aids (frequent samples, quantifications),
! malfunction detection aids (exceeding tack time, part faults, loading or unloading faults, breakdowns),

GE75-021R /B


! breakdown diagnostic aids,
! monitoring performance indicators (reliability, quality).

For each category of information, it must be ensured that:
! only the information necessary to the operator is presented, that is the info that he will use to confirm or
validate his own analyses, in particular concerning breakdowns,
! the confrontation of information from the system are confronted with information taken directly from the
installation (visual or audible),
! the information is presented in a form corresponding to the operating process in order to reduce
memorisation efforts,
! understanding of the visual signals aimed at triggering an emergency intervention are facilitated by a
reinforcement of the signal: dimension, position, flashing, combined with audible signal,
! adaptation of the access to information is possible according to the competencies acquired.

The lamps should be positioned at the correct height to be visible in the main areas of intervention of the
operators.

GE75-021R /B


F13 - Operating the installations - right-handed and left-handed operators

The service components can be activated by both hands, notably when the operating
mode requires the use of both hands.


EN 894-1 ( 4.6)

With regard to laterality, most service components can be activated using both hands. However, the service
components which require precise and/or rapid operation must be able to be activated by either hand or
designed to allow a precise and/or rapid action by the dominant hand.

Recommendations

Dominant hand
The dominant hand refers to:
! the right hand for right-handers,
! the left hand for left-handers.

Precise action
In the case of a precise and/or rapid action, the operator must be able to intervene with his dominant hand. In
particular, it is recommended that the emergency stop button be placed in the centre of the control console in
order for it to be reached equally quickly by right-handers and left-handers.

Overcrowding of operators
When two operators work side by side, the space between each station should take into account the possible
interference resulting from the fact that the operator on the left is right-handed and the operator on the right is
left-handed.

GE75-021R /B


F14 - Operating installations - Layout of control system components

The signalling devices and command components are:
" arranged in the same order, if they are used according to a fixed sequence,
" positioned in the control order,
" easily identifiable by their position in the area,
" easily and quickly accessible for the most frequent or for those working on the safety
of the use of the machine.


EN 894-1 ( 4.1.3 )

This type of organisation helps the operator to remember the operating sequence and reduces both the
response times and the risks of errors.
If the signalling measures and service components are not used in a fixed sequence, their grouping should be
determined according to the following aspects:
! the importance for the safety of the machine,
! the frequency of use in the regular functioning of the machine,
! combined use of elements in a sub-sequence.

EN 894-1 ( 4.2.6 )

If the sequences of activities require the signalling measure to be read in a pre-determined order or if they are
linked to machines which have a numbered order, the signalling measures should be placed in the same order
and should read from left to right or from top to bottom of the panel.

Recommendations

! To simplify identification and minimise the risks of incorrect manoeuvres, the luminous buttons on the
command console should be grouped into sub-groups taking into account the following criteria: types of
operation, functions, sequences of use or manoeuvre procedures, frequencies of use, modelling the
implantation of the machine.

! If the luminous buttons are grouped together by
operation type and there is a sequence between these
operations, it is recommended that the controls and
signals relating to this sequence be arranged in the
order (from left to right or top to bottom) corresponding
to the process of the sequence.
1 2 3 1
2
3

! The indication of the type of control button or warning light (cycle start, cycle restoration, etc.) should be
placed above each one in order to reduce the risks of operating errors.

! In general, the emergency stop punch button (surrounded by a yellow ring) should be placed so as to be
highly accessible for the operator and for third parties, preferably on the lower section of the command
console or table. It should be easy to identify and use thanks to its colour (red) and its size.

! Only the components necessary to the activity of the operator need to stand out from the installation.

GE75-021R /B


F15 - Operating installations -
Colours of signalling and control measures

The signalling and control system measures are easy to identify by colour code.


EN 894-2 ( 4.2.6 )
No specification

EN 61310-1 ( 5.2)

The colours should be chosen according to the information to be provided. The colours of the indicators and the
service components should conform to the following table:

Meaning
Colour Safety of personnel Conditions of the
machine or procedure
State of the equipment
Red Danger / prohibited Emergency
Yellow Warning Abnormal No meaning
Green Safe Normal General
Blue Obligatory
White, grey, black No particular meaning allocated

Recommendations
! The norm EN 60073 uses the data from the previous table and applies them to the design of warning lights
and push buttons:

COLOUR FUNCTION
NON-LUMINOUS
PUSH BUTTONS
FUNCTION
LUMINOUS
PUSH BUTTONS
FUNCTION
LUMINOUS
WARNING LIGHTS
RED ! Stop
! Out of order
! Switched off
! Stop
! Resetting
Alarm signalling faults or
abnormal conditions requiring
the intervention of the operator.
YELLOW ! Start servicing
! Execution

! Switch on
! Start

! Warning/caution
! Request for intervention
! Component not in position
GREEN ! Start
! Install
! Switch on
! Preparation
! Start
! Authorisation to start cycle
! Machine ready
BLUE Any function not colour-
specific

BLACK ! Start
! Install
! Execution

WHITE
COLOURLE
SS
! Switch on circuit
! Start function
! Circuit switched on
! Permanent condition of normal
functioning
! The emergency stop measures should be in RED.
! The number of colours should be limited (5 for static images, only 3 for dynamic interfaces) to make
differentiation by the operators rapid and reliable.
! Each colour should only represent a single data category.
Changes in state should be identified by specific warning lights.

GE75-021R /B


F16 - Operating installations - Respect of conventions

The common conventions or the stereotypes are respected.


EN 894-1 ( 4.4 )

The stereotypes of the population and other expectations of users with regard to the functioning mode of the
man/machine interface are important parameters in determining how an operator will use a particular service
component or signalling measure.

In a situation of stress, we might expect the operators to return to the stereotypes of their population, even if
they have been trained to act to the contrary.

The function, movement and position of the command and signalling means should correspond to the
expectations of the operator, whether they are the result of his professional experience or his training.

EN 60447

The correlation between the direction of the manual action on a manoeuvre component and the direction of the
final effect obtained by this action is especially important with regard to security when a false manoeuvre can
cause damage or when frequent or rapid actions are necessary.

The following tables, drawn up according to norm EN 60447, list the actions and their expected effects.

Nature of the
manoeuvre
component
Direction of the action Expected effect of the
movement
Steering wheel,
handle,
button, etc.
clockwise

anticlockwise

Handle,
lever, etc.
upwards

with conventional
downwards

rectilinear
to the right

movement to the left

moving away from the operator

moving towards the operator

x

GE75-021R /B


Type of the set of components
Type of the
action
Point of application of the action

Set of
handles,
push buttons

One above the
other

Pressure,

shafts, pull
knobs, etc.
with
antagonistic
effects

One next to the
other
tractions, etc.

Type of the set of components Type of the
action
Classification of the action
Terminal with display screen
with XY manipulator
Movement and
activation

Keyboard Hitting keys Direction of the action and point of application:
non-classified, as far as possible
Sensitive surface Touch apply the previous rules.

Action on the
lower
component
Action on the
upper
component
Action on
the left-
hand
component
Action on the
right-hand
component
x
GE75-021R /B


F17 - Operating installations - Choice of display measures

The display measures are adapted to the types of observation to be effected:
" digital display for a measured value,
" analogue display to mark a tendency in a tolerance space,
" display with memory to monitor changes.


EN 894-2 ( 4.2.5)

When a signalling measure is used, three basic types of observation are realised and are often demanded
almost simultaneously. These types of observation are:

! Reading a measured value
Reading a measured value (quantitative observation) is a task of perception in which an indicated value is
noted. To this end, the speed of modifying the indication is sufficiently low to allow a precise observation. The
figures of the digital display should not vary more than twice per second.

! Moving reading
A moving reading is a task during which a verification is made by a quick glance in order to see if the value
indicated corresponds to a pre-determined value, or if the value falls within a fixed tolerance range.

! Monitoring the modifications of a value
Monitoring the modifications of values measured constitutes a task during which the observer notes the
direction and speed of modification of the values measured. This type of observation is characteristic of process
operating tasks.

Recommendations

The choice of the signalling measures is effected according to the task:
! Digital display to effect the precise results:

! Analogue display with no memory to mark the trends or adjust a parameter:

! Analogue display with memory to monitor the changes, favour the diagnostics and the forecasts:

GE75-021R /B


F18 - Operating installations - Analogue display

In the case of analogue displays:
" the pointers occupy the same angular position to indicate the normal state,
" the correct zones are marked in green and the incorrect zones in red.


EN 894-2 ( 4.2.6)

An analogue display is a display in which the status information is represented by a length, an angle or another
physical measure. In the case of visual displays, the information can be represented by the movement of a
pointer, the length of a bar chart or a similar visual measure. In the case of audible signalling measures, the
information can be represented as a function of pitch or sound intensity level. In the case of tactile signalling
measures, the information can be represented by the vibration (frequency or amplitude) or the movement of the
display.

To facilitate the detection of abnormal conditions to the maximum, the
signalling measures should be placed so that all the pointers are in
the same angular position when they indicate the normal status (see
figure).

The homogenous grouping of pointer displays improves the detection of a discrepancy.

Recommendations

! Adapt the scales so that the grouped analogue displays indicate their normal status by the same position.
! Use a colour (green) to indicate the zones where the measurement is considered normal and another colour
(red) for those where the measurement is abnormal.

FAULT
GE75-021R /B


F19 - Operating installations - Choice of signals

The signals relating to safety are designed so that their meaning is obvious, clear and
unambiguous to the user.


EN 61310-1 ( 4.1)

Active signals should be used to signal a risk (dangerous phenomenon) and to request that the personnel take
particular measures.

Passive signals should be used as a warning in the event of permanent probability of risk or to provide
information concerning the position, for example emergency exits or emergency stop measures.

If possible, visual signals should be used.

Additional means to visual signals, such as audible or tactile signals, should be chosen and used in cases
where:
! the operator has a visual deficiency (blindness, colour blindness),
! the operator needs to look elsewhere when working or activating the controls,
! the people exposed are out of sight of the operator,
! the people exposed cannot see the warning signals.

The table below, extracted from the norm, provides some examples of signals:

Signal Visual Audible Tactile
Active Start/stop
or change of:
! colour
! brightness
! contrast
! saturation
Flashing
Change of position
Start/stop
or change of:
! frequency
! intensity (sound level)
Type of sound
Vibration
Change of position
Click/snap
Positioning with positive reaction
Passive Security signal
Additional signal
Marking
Shape, colour.
Silence Shape
Roughness of the surface
Relief
Relative position

GE75-021R /B


F20 - Loading and unloading parts - Tempo of the operator

" The tempo of the operator is not strictly linked to the cycle of an automatic or semi-
automatic machine.
" Regulation is at level # 3 (Renault ergonomic analysis method reference). The result is
evaluated according to the objectives of the project.


EN 614-1 ( 4.5)

The independence of the operator can be ensured by stock buffers, supply devices, robots, etc.

Recommendations
! For continual execution of tasks of loading and unloading, the dependence can be regulated:
! by validation of the cycle start by the operator,
! or by creating parts-in-progress.
The "regulation" criterion of the Renault ergonomic analysis method allows an evaluation of the constraint on
a scale with five levels. The regulation is acceptable for levels ! 3 (see evaluation sheet in appendix 1).

! If it is a case of multitasking, parts-in-progress must be created at the line entry and/or exit, the quantity of
which is a function of:
! the longest activity sequence, which cannot be interrupted (control, changing tools, etc.),
! rest times, if it is desired that the installation work during the break.
The Renault ergonomic analysis method does not apply to this type of situation.

! Bringing supply and evacuation closer together, for example by designing a U-shaped line, offers several
advantages:
! the reduction of movements of operators,
! greater flexibility of organisation and exploitation,
! a reduction in conveyors belts when the pallets are returned,
! a gain for the supply chain.

GE75-021R /B


F21 - Loading and unloading parts - Postures

" There are no uncomfortable postures, significant twisting or flexing of the body,
movements likely to cause illnesses or bodily injuries, including in defective modes.
Support for the body is appropriate in order to avoid off-balance postures.
" The posture constraint is at level # 3 (Renault ergonomic analysis method reference).
The result is evaluated according to the objectives of the project.


EN 614-1 ( 4.1.2 )
! uncomfortable postures, for example twisting and flexing the body, as well as prolonged activities causing
bodily fatigue should be avoided,
! an appropriate posture and support for the body is to be ensured. These supports should be of a size and
positioned so as to avoid off-balance postures.

Recommendations

The "posture" criterion of the Renault ergonomic analysis method allows and evaluation of the constraint on a
scale with five levels. The posture is acceptable for levels ! 3 indicated in the extract from the evaluation sheet
below.

3
Hands between
the heart and
the shoulder
2
3 4
Hands at
head height
Elbow at
shoulder
height
Arms
outstretched
with no support
Slight twisting
Leaning
30 to 45
Leaning
$ 45
Leaning
to the side
Considerable
twisting
Leaning
30 to 45
Risk of osteo-articular parthologies
(including lumbar)
5 4
Leaning
considerably
to the side
Twisting of
almost 90
Flexing +
and Rotation
of back
Leaning
$ 45
Leaning
backwards
Crouching
or
kneeling
POSITION OF THE UPPER LIMBS < 20% tcy 20% to > 30% tcy
JOINTS USED
30% tcy
or or or
< 50 f/h 50 100 f/h > 100 f/h
POSTURE
FRONTAL
WITHOUT
SUPPORT
LATERAL
POSITION OF THE BACK
Prolonged hyperextension
or hyperflexingof wrist
Intense repeated
tightening or
pressure of fingers
Repeated maximum
supinationmovements
Global level of station:
maximum level observed
weighted by the sum of the
frequencies or the holding times
FRONTAL
WITH SUPPORT
POSITION OF
THE HANDS AND
ARMS
Leaning
slightly,
10 to 30
Leaning
slightly to
the side 3
Hands between
the heart and
the shoulder
2
3 4
Hands at
head height
Elbow at
shoulder
height
Arms
outstretched
with no support
Slight twisting
Leaning
30 to 45
Leaning
$ 45
Leaning
to the side
Considerable
twisting
Leaning
30 to 45
Risk of osteo-articular parthologies
(including lumbar)
5 4
Leaning
considerably
to the side
Twisting of
almost 90
Flexing +
and Rotation
of back
Leaning
$ 45
Leaning
backwards
Crouching
or
kneeling
POSITION OF THE UPPER LIMBS < 20% tcy 20% to > 30% tcy
JOINTS USED
30% tcy
or or or
< 50 f/h 50 100 f/h > 100 f/h
POSTURE POSTURE
FRONTAL
WITHOUT
SUPPORT
LATERAL
POSITION OF THE BACK
Prolonged hyperextension
or hyperflexingof wrist
Intense repeated
tightening or
pressure of fingers
Repeated maximum
supinationmovements
Global level of station:
maximum level observed
weighted by the sum of the
frequencies or the holding times
FRONTAL
WITH SUPPORT
POSITION OF
THE HANDS AND
ARMS
Leaning
slightly,
10 to 30
Leaning
slightly to
the side
GE75-021R /B


F22 - Loading and unloading parts - Gripping parts

" It is possible to ensure good lifting and a good balance of the parts.
" Lifting and positioning are effected with no risk of parts being dropped or hands being
jammed, including in defective modes.


EN 614-1 ( 4.1.4)

The gripping components should be studied, chosen and arranged so that the application of the physical effort
necessary is as low as possible without the application of these principles having negative effects on health and
safety.
Positioning should be effected with no risk of parts being dropped or hands being jammed.

GE75-021R /B


F23 - Loading and unloading parts - Handling efforts

" The physical efforts during the execution of the task are limited to acceptable levels,
including in defective modes.
" The effort constraint is at level # 3 (Renault ergonomic analysis method reference).
The result is evaluated according to the objectives of the project.


EN 614-1 ( 4.1.4 )

With regard to handling, these levels depend on the weight, shape, size, mass distributions and the position of
the objects.

Recommendations

The "effort" criterion of the Renault ergonomic analysis method allows and evaluation of the constraint on a
scale with five levels. The effort is acceptable for levels ! 3 indicated in the extract from the evaluation sheet
below.

In any case, the use of an assist device should be easy and should not induce a longer handling time of the
parts.

EFFORT
Frequency
of
repetition
per hour
0,3
% 1,5
1
#
5% #
5
1,5
% 2,5
2,5
% 4
4
% 6
6
% 9
9
% 12
12
% 16
16
% 21
21
% 28
$ 28
Weights or efforts (Kg ou DaN)
21 to
#
30%
6 to
#
10%
11 to
#
20%
31 to
#
40%
41 to
#
60%
61 to
#
80%
81 to
# 90%
91 to
100%
6 to
#
30
31 to
#
60
61 to
#
90
91 to
#
140
141 to
#
220
221 to
# 330
331 to
#
500
$
500
1 1
1 1
1
1
2 2
2 2
2 2
2
2
3 3 3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3 3
3 3
2
EFFORT
Frequency
of
repetition
per hour
0,3
% 1,5
1
#
5% #
5
1,5
% 2,5
2,5
% 4
4
% 6
6
% 9
9
% 12
12
% 16
16
% 21
21
% 28
$ 28
Weights or efforts (Kg ou DaN)
21 to
#
30%
6 to
#
10%
11 to
#
20%
31 to
#
40%
41 to
#
60%
61 to
#
80%
81 to
# 90%
91 to
100%
6 to
#
30
31 to
#
60
61 to
#
90
91 to
#
140
141 to
#
220
221 to
# 330
331 to
#
500
$
500
1 1
1 1
1
1
2 2
2 2
2 2
2
2
3 3 3
3
3
3
3
3
3 3
3
3
3
3
3
3
3
3 3
3 3
2
!
! !
! !
"
" !
"
!
! !
! "
"
"
#
"
$
$
$
$
$ $
$
$
#
#
#
#
Recommendations for handling aids
Assist device required for people with restriction
on carrying heavy loads
Assist device recommended, with possibility of:
either carrying several parts at the same time,
or using assistance for functions other
than handling.
Assist device obligatory
Automation or assistance allowing several parts
to be carried at the same time,
or implementation of organisational locks
"
!
$
#
#
"
CONDITIONS:if one of the following conditions applies,
multiply the real weight by 2 in the grid opposite .
- Turning the load with risk of damage.
- Lifting and holding load with arms spread or outstretched
- Delicate positioning or hanging with prolonged balancing in
one hand only
- Lifting pieces with finger ends and/or strong pressure of fingers
or wrist
- Non-rigid load or load without clear hold.
- Load lifted in sitting position
- Effort directed in abduction (arms spread outwards )
Holding
time
(% of tack
time)
GE75-021R /B


F24 - Controlling the parts - Information and means

All information (control plans, documentation, etc.) and all means necessary for the
execution of the task are made available to the operator.


EN 614-1 ( 4.2)

No specification

Recommendations

! The control plan should specify as early as possible what the operator needs in terms of information and
means to validate (or not) the quality of a part by reducing the differences in interpretation to a minimum.

! The needs are determined according to the feedback necessary for the operation of the installations. In
particular, we distinguish:
! the line-side control which allows a rapid return of partial information for the operator, for example after
changing tools or equipment,
! more exhaustive controls, such as 3D controls, for less frequent information feedback.

! The documentation at the station should be clear and understandable.

! The lighting level should be strengthened above the control station and adapted to the intricacy of the faults
to be detected. For example:
! 750 lux for work on small parts,
! 1500 to 2000 lux for work on very intricate or very small parts.

GE75-021R /B


F25 - Controlling the parts - Postures, gripping, efforts

movements likely to cause illnesses or bodily injuries. Support for the body is
appropriate in order to avoid off-balance postures.
! It is possible to ensure good lifting and a good balance of the objects.
! Lifting and positioning are effected with no risk of the objects being dropped or hands
being jammed.
! The physical efforts made while the task is being effected are limited to acceptable
levels. There is no prolonged static muscular tension.


EN 614-1 ( 4.1.2 )
! uncomfortable postures, for example twisting and flexing the body, as well as prolonged activities causing
bodily fatigue should be avoided,
! an appropriate posture and support for the body is to be ensured. These supports should be of a size and
positioned so as to avoid off-balance postures.

EN 614-1 ( 4.1.4)
Any prolonged static muscular tension (such as that caused by holding the hands or arms in a raised position)
should be avoided.

Recommendations

! The postures adopted for lifting, replacing and withdrawing the parts are determined by:
! the height of the work surface, excl. control fitting,
! the height of control fitting,
! the modalities of inserting the part in the fitting.

! The risks or difficulties are determined by:
! the characteristics of the parts (slippery, hot, etc.),
! the weight of the parts,
! the gripping conditions,
! the postures adopted for lifting replacing and withdrawing the parts,
! the postures adopted for controlling the parts.

GE75-021R /B


! For parts weighing 9 kg or more, the following should be provided:

from 9 to <16 kg from 16 to < 21 kg 21 to < 28 kg 28 kg or more
! A table with rollers or
any system allowing
the part to be slid.
! An aid for tipping the
part, especially in the
case of risks of
scratching.
! An assist device if one or
other of the following
conditions apply:
! the posture is
uncomfortable* and the
frequency greater than 30
times / hour,
! the frequency is greater
than 60 times / hour,
! the gripping conditions
are poor: arms spread,
gripping with end of
fingers, turning the part
with risk of damage, risk
of slipping or jamming,
etc.
! An assist device if one or
other of the following
conditions apply:
! the posture is
uncomfortable* and the
frequency greater than 5
times / hour,
! the frequency is greater
than 30 times / hour,
! the gripping conditions
are poor: arms spread,
gripping with end of
fingers, turning the part
with risk of damage, risk
of slipping or jamming,
etc.
! An obligatory
assist device.

* according to the Renault ergonomic analysis method, a posture is considered as being uncomfortable at
levels 4 and 5 (see the grid on sheet no. 21).

When the control sequences last several minutes, provide for the possibility of effecting the control in a
sitting position.

GE75-021R /B


F26 - Changing tools and equipment - Information

All information necessary to the execution of the task are made available to the operator
so as not to impose unacceptable demands on him in terms of speed of intervention


EN 614-1 ( 4)

No specification

Recommendations

! Adequate information measures allow the status of the tools to be controlled and the reliability of the
changes to be programmed and guaranteed.

! For each tool, the operators must know:
! the number of cycles effected since the last change,
! the theoretical frequency of change,
! the real previous, or even the 2 previous, frequency(ies),
! the warning threshold.

! This information should allow the operators to be responsible for decision-making in order to combine
several tool changes, thus limiting the stoppage times of the machines.

GE75-021R /B


F27 - Changing tools and equipment - Postures, gripping, efforts

movements likely to cause illnesses or bodily injuries.
" It is possible to ensure good balance and a good grip of objects held in the hand.
" Lifting and positioning are effected with no risk of the objects being dropped or hands
being jammed.
" The physical efforts made while the task is being effected are limited to acceptable
levels. There is no prolonged muscular tension.
" The forces are of a low level for movements requiring a high level of precision.
" The combination of posture and the weight of the tools or equipment does not
demonstrate dorso-lumbar risks.


EN 614-1 ( 4.1.2)

! Accessories should be provided for operations requiring a high level of precision (winches, support bars,
stops, etc.). The work area should be sufficiently large to accommodate such accessories.
! Movements of rotation requiring the application of large forces should be avoided; this is particularly true for
the extreme positions of the hand / arm joints.
! Any prolonged static muscular tension (such as that caused by holding the hands or arms in a raised
position) should be avoided. The weight of the equipment held in the hand can be an important cause of
muscular fatigue when prolonged durations of use are required and, consequently, its effect should be
reduced, for example by supporting the said equipment using a suspension system.

GE75-021R /B


Recommendations

! Work surfaces and volumes
The zones reached depend on the weight of the tools
and equipment and should fall within the limits opposite.
These limits are understood:
! with a maximum twisting of 15,
! without holding parts in extreme positions.
In particular, the following should be avoided:
! postures leaning more than 45,
! twisting more than 30,
! arms above shoulder height.
The positions in lower parts (height of 500 to 600 mm)
are acceptable insofar as the operator can bend his legs.
Always provide for a hollow for the feet, thus allowing the
operator to:
! move in as close as possible,
! to be supported on his lower limbs.
For weights greater than 16 kg, an assist device should
be implemented according to the recommendations
indicated on sheet F25 - Controlling parts - Postures,
gripping, efforts.

! Gripping
The following points are recommended:
! good design for gripping points in order to avoid, in
particular, uncomfortable positions of the hand and
forearm, as well as the risk of jamming when
changing tools.
! elimination of obstacles interfering with lifting the
tools or the risks of cutting or collisions,
! use of adapted aids or mechanical measures to
block parts, suspension systems with stabilisers for
heavy tools.
! wearing of gloves, which alter sensitivity, be taken
into account.

< limit of the position
of lower limbs
1700
1100
500
1500
12 16 Kg
9 <12Kg
6 <9 Kg
1300
600 450 300
300
<6 Kg
Heights and depths en mm
GE75-021R /B


F28 - Changing tools and equipment - Openings and access holes

The sizes of access holes:
! respect the normative recommendations,
! take into account the task to be effected and the means used.


EN 547-1 and EN 547-2

These norms provide the dimensions of the openings and passages for each part of the body which is to access
via these holes: upper body, arm, hands, etc.

Recommendations

The width of the openings for the passage of elbows and shoulder should be:
! 545 mm for a man in the 95
th
centile
! plus the space necessary to avoid collisions,
! i.e. a minimum width of 745 mm.

A greater width should be allowed for if considerable movement of the upper limbs is necessary, notably with
elbows spread.

GE75-021R /B


F29 - Maintenance or settings - Executing a function

Executing a function is possible from different points when there are certain
imperatives: speed, precision, safety or health.
Adequate means are implemented to allow efficient information feedback concerning
the adjustments or fine-tuning effected (e.g. position sensors, mobile console, video,
etc.)


EN 894-1 ( 4.3.1)
Provide the necessary measures for additional service components when superfluousness can improve security
as a whole.
Certain characteristics of the system sometimes require that the execution of a given function be possible from
different points, so that imperatives of speed, precision, safety and health may be ensured.

Recommendations

The mobile command console allows skilled personnel to enter the installation, effecting adjustment operations
as close as possible to the installation, without relying on the central console.
In this case, the command of movements must be effected:
' with hands occupied and sustained action,
' slowly and with reduced effort.

Using this console cancels the functions of the main console.

GE75-021R /B


F30 - Maintenance or settings - Spaces, openings and access holes

" The spaces and access allow significant twisting and flexing of the body or off-
balance positions to be avoided.
" The spaces and access holes take into account:
" size and corpulence,
" postures and gestures,
" the position of the hole in relation to the person,
" the frequency and duration of the task,
" the transport of tools,
" the length of passage,
" the types of protective clothing and equipment,
" the level of risk and the space for rapid movement in an emergency,
" the surrounding conditions (darkness, heat, humidity, noise, ventilation).

EN 547-1 and EN 547-2
These norms provide the dimensions of the openings and passages for each part of the body which is to access
via these holes: upper body, arm, hands, etc.

Recommendations

! The adjustment, lubrication and maintenance components (distributor, electrical box, detector, etc.) should
be accessible in total security and, when possible, from the ground and outside dangerous zones. If this is
not possible, means of access and intervention must be provided for (platform, stairs, etc.).
! Provide platforms for access in total security, as in the third photo.
! Provide assist devices for carrying components when they are heavier than 16 kg and the postures are poor
or off-balance.
! After the detailed study phase, the following should be provided for:
! the conditions of accessibility of repair material,
! lifting means integrated into the machines,
! connections to energy sources (electric, pneumatic, etc.),
! specific equipment for the means,
! walkways limiting movements and reducing changes in level as far as possible.

GE75-021R /B


F31 - Maintenance or settings - Efforts



EN 614-1 ( 4.1.4)

The constraint imposed by the work equipment on the physical strength of the operator while working should be
limited to acceptable levels. With regard to handling, these levels depend on the weight, shape, size, weight
distribution and position of the objects, the duration and frequency of the application of effort, the posture of the
operator (sitting or standing station) and the trajectory of his movements, the work rules and methods applied
and the specific characteristics of the forecast population of operators (for example, the sex, age, health,
physical characteristics and training of the operator).

! When the physical effort to be applied cannot be exercised by muscle groups capable of responding to the
force requirements, mechanical assistants should be provided for.
! Any prolonged static muscular tension (such as that caused by holding the hands or arms in a raised
position) should be avoided. The weight of the equipment held in the hand can be an important cause of
muscular fatigue when prolonged durations of use are required and, consequently, its effect should be
reduced, for example by supporting the said equipment using a suspension system.
! The application of physical effort should be reduced by using gravity or other measures.
! The service components, gripping components, handles and pedals on the work equipment should be
studied, chosen and arranged so that the application of the necessary physical effort is as small as possible
without the application of this principle having negative effects on health or safety.
! According to constraints of strength, size, the shape and position of service components, any unbalancing of
the body and limbs is to be avoided. If prolonged and frequent use is necessary, the service components
should be used in a sitting position.
! The distribution of the weight of equipment held in the hand should ensure good balance.

GE75-021R /B


F32 - Supply and evacuation of consumables and waste - Postures and efforts

" The combination of posture and the weight of the object to be lifted does not
demonstrate dorso-lumbar risks.


EN 614-1 ( 4.1.4 )

Recommendations

The supply and evacuation of consumables and waste can be factors of risk and causes of loss of operating
output.

! After the "preparation of plans or envelope studies" phase, the following must be identified:
! the consumables which will be used (cardboard, oils, etc.),
! the type and quantity of the waste produced per unit of time (team, day, etc.).

! During the "detailed design or detailed study" phase, the following must be studied:
! technical solutions for the evacuation of waste in order to reduce the polluted or dirty zones within and
around the installations,
! the implementation of an assist device for weights greater than 20 kg.

! For low frequencies of changes of consumables (1 or 2 times per month) and for weights below 28 kg,
supply and evacuation can be planned for two operators instead of using the assist device.

! Position the elements to be lifted a minimum of 500 mm from the ground and provide adapted handles.

GE75-021R /B


F33 - Repetitive assembly operations - Diversity and complexity

" The work situation does not impose the implementation of too demanding information
processing or memorisation procedures on the operator.
" The complexity, i.e. the number of decisions to be taken in a given time, is neither too
excessive nor too low.
" Referring to the Renault ergonomic analysis method, the decision constraint is at
level # 3 (exceptionally level 4 for a regulation # 2).


ISO 10075-2 ( 4.2)

If the complexity is excessive for the planned population of operators, decision-making aids should be used.
Too low a level of complexity should be avoided as this may cause monotony or saturation.

Recommendations

The Renault ergonomic analysis method evaluated the complexity on a scale of five levels of constraints using
the "decision" criterion. The decision constraint should be:
! level ! 3 for level 3 regulation (sheet no. 34),
! acceptable at level 4 for regulation < 3.

! Product diversity

! Limit the number of references to 5 for the parts or components such as screws, staples, etc. If there are
more than 5 references, the choice for the operator should be reduced to a maximum of 5 by means of:
! an action on the product,
! implementation of a help for the choice (Rack, light device, ..).

! Ensure physical identification of each reference by means of:
! a visual code (digital, alphanumeric, signs, symbols, etc.) whose typography is readable and highly
discriminating,
! tactile differentiation.

! Limit the time and movements between information reading on the reference and the withdrawal of the parts.

! Ensure the possibility for the operator to control the supply of the correct reference in the correct position
(labels identical on both sides, etc.).

! Create divisions tending to favour control at stations downstream, preferably in the same work shop.

! Favour the installation working at fewer than 4 batches/hour.

! Have the batch change validated by the operator.

GE75-021R /B


! Fitability

! Implement location notches.

! Ensure that the positioning is obvious, easy and does not require a high level of skill.

! Eliminate blind work if it is linked to a delicate positioning or a risk of error.

! Complexity of the task

! Limit the number of operations to 10 per cycle.

! Limit the number of tools as far as possible (screw guns, pincers, hammer, hook, paintbrush, stapler,
cutter, etc.), as well as the diversity of adapters used on these tools.

! Limit, as far as possible, the cases of interpretation possible for adjustment and/or control operations.

! Ensure that the positioning of supplies and tools conforms to the operating mode.

GE75-021R /B


F34 - Repetitive assembly operations - Regulation

" The operator has the possibility of regulating the progress of the operations which he
carries out.
" Referring to the Renault ergonomic analysis method, the regulation constraint is at
level # 3.


ISO 10075-2 ( 4.2)

Recommendations

The Renault ergonomic analysis method evaluates the regulation possibilities on a scale of five levels of
constraints using the "regulation" criterion. The regulation constraint should be at level "3.

The regulation criterion measures the possibility for the operator to:
! manage the components of industrial variability:
! manage the diversity of the operations and commitments,
! manage unforeseen events of malfunctions,
! achieve the production objectives in each work cycle,
! be able to vary his work speed slightly according to his physical and mental health,
! continue his activity temporarily during micro-breaks due to stoppages upstream or downstream of his station.

To favour regulation, it is recommended that the following elements be taken into account:

! Tack time. The possibilities for regulation fall with a reduction in the tack time.

! Work space in the case of continual advance of the product (the operator accompanies the advance of the
product). The regulation space is determined by the technical and organisational elements such as: the length
of the pipes of the equipment, the movement of the bench vices, the interference characterised by the
operators upstream or downstream, the type of supply on the line edge, etc.

! Operating modes. The operator should have the possibility of anticipating:
! the lifting of parts and / or adequate tools,
! the collection of information (anticipation several cycles before the arrival of a specific product).

! Synchronisation of actions. The synchronisation of operating sequences between several operators reduces
the possibilities for individual regulations by "imposing" a coordinated rhythm.

GE75-021R /B


F35 - Repetitive assembly operations - Postures

" Referring to the Renault ergonomic analysis method, the posture constraint is at level
# 3.


EN 614-1 ( 4.1.2 and 4.1.4)

Recommendations

The Renault ergonomic analysis method analyses postures on a scale of five levels of constraint. The posture
constraint should be at level "3. The table below reproduces an extract from the posture sheet for this method.

- Movements / mn
> 20 m
- Climbing an obstacle
> 500 mm
- Going up or down:
- 3 or more steps, hands full
- step(s) with bulky load
- Stepping backwards >30%of
tack time
- Crouching or kneeling for
duration > 5 sec
Large
extension
backwards
or head
looking
$ 60
3
4
5
- Standing still with no
possibility of moving
- Going up or down:
- 1 or 2 steps, hands empty
- Stepping forwards or
sidewardswith posture level 3
and with no interference
between operators
See table of
fittings and clips
See table of fittings
and clips
or
- Flexion or
extension of wrist
> 60 and effort
> 3Kg
- Risknoticedof peri-
articular complaint
- Movements / mn
between14 and20 m
- Climbing an obstacle of
between 300 and 500 mm
- Going up or down:
- 1 or 2 steps, hands full
- More than 2 steps, hands
empty,
- Stepping sidewardswith
posture level 4 or with
interference between
operators
- Stepping backwards # 30%
of tack time
duration of # 5 sec
See table of
fittings and clips
or
- Striking with hand
- Repeated rotations of
hand-forearm
- Considerable
screwing jolts
-Use of vibrating or
percussive tool
- Flexion or extension
of wrist > 60
Head
looking
upwards
between 40
and 60 with
duration
> 5 sec or
rotation > 45
H3 k3
H4 k4
H5 k5
$ 60 $ 90 $ 60 $ 60
10 30 30 60 20 40 10 30
(2) (2) (2) (2)
30 60 60 90
40 60
30 60
(2) (2) (2) (2)
B3 A3 D3 C3
B4 A4 D4 C4
B5 A5 D5 C5 E5
E4
Hand
above the
head
or
shoulder
raised
or
or
or
Without
upport or with
duration or
effort
- withupport (1)
or
- Duration# 2 sec
andeffort # 2 Kg
HEAD
UPPER LIMB
FINGER-HAND-
WRIST
MOBILITY
OF LOWER
LIMBS
L
E
V
E
L
BACK
ROTATION
ANGLE
FLEXION
- duration ( 5 sec
or
effort ( 2 kg
- Duration # 5 sec
and
- effort # 2 Kg
ARM/HAND
Armat
30 to < 90
Hand at
shoulder height
Hand at
head height
Armat 90
or arm
outstretched
upwards
Arm
60 at 90
or arms
outstretched
upwards
Hand
above the
head
Shoulder
raised
F3 G3
F4 G4
F5
Hand at head
height
Good Bad
< 30 30 60 > 60
"H" : FITTINGS AND CLIPS
H2 H3 H4 # 3 Kg # 2 Kg
H3 H4 H5
> 3 6 Kg > 2 4 Kg
H4 H5 H5 > 6 10 Kg > 4 6 Kg
H5 H5 H5 ( 10 Kg ( 6 Kg
Flexion - Extension
of Hand
Effort exercised by the
fingers according to the
contact area
11 to 100x/h
or duration of
between 6
and 30% of
tack time
> 100x/h
or duration
> 30% of
tack time
1
2
3
4
5
# 10x/h or
duration #
5%of tack
time
3/4
(3)
4 5
4 3 2
1 2 3
2 1 1
1 1 1
GLOBAL STATION RATING
Maximum
level
observed
(1) Example of comfortable supports
- between the upper thigh and the navel
- support on one hand
- possibility of moving the feet freely
(2) Combination of back positions. If
there is a combination of 2 positions at the
limits, 1 level should be added according to
the following example: A3 nearly 30 and
C3 nearly 30, gives a rating of level 4.
(3) Rating
- 3 if the effort linked to the level 5 posture
is # 6 kg
is > 6 kg
- Movements / mn
> 20 m
> 500 mm
- Going up or down:
- Stepping backwards >30%of
tack time
duration > 5 sec
Large
extension
backwards
or head
looking
$ 60
3
4
5
- Going up or down:
between operators
See table of
fittings and clips
and clips
or
- Flexion or
extension of wrist
> 60 and effort
> 3Kg
articular complaint
- Movements / mn
between14 and20 m
- Going up or down:
empty,
operators
of tack time
duration of # 5 sec
See table of
fittings and clips
or
hand-forearm
- Considerable
screwing jolts
percussive tool
of wrist > 60
Head
looking
upwards
between 40
and 60 with
duration
> 5 sec or
rotation > 45
H3 k3
H4 k4
H5 k5
$ 60 $ 90 $ 60 $ 60
10 30 30 60 20 40 10 30
(2) (2) (2) (2)
30 60 60 90
40 60
30 60
(2) (2) (2) (2)
B3 A3 D3 C3
B4 A4 D4 C4
B5 A5 D5 C5 E5
E4
Hand
above the
head
or
shoulder
raised
or
or
or
Without
upport or with
duration or
effort
- withupport (1)
or
- Duration# 2 sec
andeffort # 2 Kg
HEAD
UPPER LIMB
FINGER-HAND-
WRIST
MOBILITY
OF LOWER
LIMBS
L
E
V
E
L
BACK
ROTATION
ANGLE
FLEXION
- duration ( 5 sec
or
effort ( 2 kg
- Duration # 5 sec
and
- effort # 2 Kg
ARM/HAND HEAD
UPPER LIMB
FINGER-HAND-
WRIST
MOBILITY
OF LOWER
LIMBS
L
E
V
E
L
BACK
ROTATION
ANGLE
FLEXION
- duration ( 5 sec
or
effort ( 2 kg
- Duration # 5 sec
and
- effort # 2 Kg
ARM/HAND
Armat
30 to < 90
Hand at
shoulder height
Hand at
head height
Armat 90
or arm
outstretched
upwards
Arm
60 at 90
or arms
outstretched
upwards
Hand
above the
head
Shoulder
raised
F3 G3
F4 G4
F5
Hand at head
height
Good Bad
< 30 30 60 > 60
H2 H3 H4 # 3 Kg # 2 Kg
H3 H4 H5
> 3 6 Kg > 2 4 Kg
H4 H5 H5 > 6 10 Kg > 4 6 Kg
H5 H5 H5 ( 10 Kg ( 6 Kg
Flexion - Extension
of Hand
contact area
11 to 100x/h
or duration of
between 6
and 30% of
tack time
> 100x/h
or duration
> 30% of
tack time
1
2
3
4
5
# 10x/h or
duration #
5%of tack
time
3/4
(3)
4 5
4 3 2
1 2 3
2 1 1
1 1 1
Maximum
level
observed
(3) Rating
is # 6 kg
is > 6 kg
GE75-021R /B


F36 - Repetitive assembly operations - Efforts

levels.
" Referring to the Renault ergonomic analysis method, the effort constraint is at level #
3.


EN 614-1 ( 4.1.2 and 4.1.4)

Recommendations

The Renault ergonomic analysis method analyses efforts on a scale of five levels of constraint. The effort
constraint should be at level "3. The table below reproduces an extract from the posture sheet for this method.

Holding
time
(% of cycle
time)
Frequency
of repetition
per hour
# 5% # 10
Efforts ou weight (Kg)
21
# 30%
6
# 10%
11
# 20%
31
# 40%
61
# 80%
91
100%
11
# 30
31
# 67
68
# 120
121
# 190
291
# 490
$ 721
81
# 90%
491
# 720
41
# 60%
191
# 290
(1 to
2
( 2 to
4
( 4 to
6
( 6 to
9
( 9 to
12
(12 to
15
(15 to
20
()* to
25
( 25
1 1
1
2 2
2 2
2 2
3 3 4
3
3
3
3
3
2
3
3
3
3 3
3 3
4
4 4
4
4
4
4
4
4
4
4 2
4
5
5
5 5
5 5
5 5
5 5
4 4 5 5
5 5
3 3 4 4 5 5
#+
1
1
1
3
2
3
1
3
2
CALCULATION RULE
When different loads are handled, proceed
with an evaluation by using the following two
formulae and by retaining the most
unfavourablerating:
-average weight of all the loads >1 kg and
sum of frequencies or duration of carrying
these loads (see note).
- weight of the heaviest load (or the most
significant loads) and frequency or duration of
carrying the load.
Note:
- a calculation of average weight adjusted
for the frequenciescan be effected, when
the rating is located at the limit between two
levels (see user manual).
- The loads # 1 kg are only taken into account
when the loads are below this level.
COEFFICIENTS OF WEIGHTINGS THE EFFORTS OR WEIGHT
0,5
0,5
0,7
1,5
1,5
1,5
1,5
1,5
1,5
1,5
1,5
2
2
Coefficient References
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
Rotation of a platform (or rotating system) using two hands, with a good support on a non-skid floor
Pushing or pulling a trolley, with a good support on a non-skid floor
Pushing or pulling an assist device, with a good support on a non-skid floor
Turning the load with risk of damage.
Lifting and holding (duration > 5 sec) of the load with arms spread (> 1,000mm) or outstretched (distance > 500mm)
Delicate positioning or hanging with prolonged balancing in one hand only
Non-rigid load, or without clear hold, or with a centre of gravity considerably offset in relation to the axes of the load
Lifting or placing a load > 6 Kg or bulky*, to a height (position of the hands) < 500 mm or >1,500 mm
Carrying a load > 6 kg, lifting parts with finger ends
Carrying a load > 6 kg going up or down one or several steps
Carrying a load > 6 kg with obligatory movement of more than 5 m
Effort of abduction with a single hand (arm and hand spread towards the exterior)
Load lifted in sitting position
COEFFICIENTS OF WEIGHTINGS THE EFFORTS OR WEIGHT
0,5
0,5
0,7
1,5
1,5
1,5
1,5
1,5
1,5
1,5
1,5
2
2
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
GE75-021R /B


5 List of documents cited
NOTE : for the documents not-dated, the last version is applicable.
ISO 7730 : moderate thermal atmospheres. Determination of PMV and PPD indexes and
specifications of conditions of thermal comfort.
ISO 10075-2 : Ergonomic principles concerning the mental work load. Part 2: design principles.
EN 547-1 : Machine safety. Measurement of human body. Part 1: principles of setting the
dimensions required for the openings destined for the passage of the whole body in
the machines.
EN 547-2 : Machine safety. Measurement of human body. Part 2: principles de of setting the
dimensions required for the access holes.
EN 563 : Machine safety. Temperatures of tangible areas. Ergonomic data for setting
temperature limits of hot surfaces.
EN 614-1 : Machine safety. Ergonomic design principles. Part 1: terminology and general
principles.
EN 894-1 : Machine safety. Ergonomic specifications for the design of signalling measures and
service components. Part 1: general principles of interactions between personnel
and the signalling measures and service components.
EN 894-2 : Machine safety. Ergonomic specifications for the design of signalling measures and
service components. Part 2: signalling measures.
EN 1837 : Machine safety. Integrated machine lighting.
EN 60073 : Basic principles and safety principles for man-machine interfaces, marking and
identification. Coding principles for the indication measures and command
components.
EN 60447 : Man-machine interface (IHM); manoeuvring principles.
EN 61310-1 : Machine safety. Indication, marking and manoeuvring. Part 1: specifications for the
visual, audible and tactile signals.
NF X 35-103 : Ergonomics. Principles of visual ergonomics applicable to lighting of places of work.
NF X 35-104 : Postures and dimensions for men at work on machines apparatus.
EB75.81.325 : Industrial machines and installations . Safety. Working conditions. Acoustics.
Technical specifications
EB75.82.125 : Industrial machines and installations. Ergonomics. Technical specifications
Renault ergonomic analysis method
ND 2052 : INRS documents 'Cahier de notes documentaires' Work hygiene and safety no.
167 , 2
nd
quarter 1997
GE75-021R /A Appendix 1 Normative

ERGONOMIC ANALYSIS SHEET
Repetitive activities
N
Site : Department Shop or UET :
Product / Component / Line:
Station:
Number of operators:
Tack time: Hourly frequency:
SYNTHESIS
PHYSICAL CONSTRAINT COGNITIVE CONSTRAINT
POSTURE REGULATION
1 2 3 4 5 1 2 3 4 5
1 1
2 2
EFFORT 3
TARGET
COMPLEXITY 3
TARGET
4 4
5 5
JOINT ZONES USED NATURE OF COGNITIVE DEMANDS
COMPLEXITY FUNCTIONING
Zone Reference Tick the factors with faults $ 3 MACHINES - EQUIPMENT - TOOLS
Neck vertebrae DIVERSITY OF PARTS and FASTENINGS
Back REGULATION SUPPLY - PACKAGING
Shoulders
Tick the factors with faults $ 3
OPERATINGMODE
Elbows WORK TEMPOS ACCESSIBILITY - POSITIONINGOF PARTS
Wrists SPACE ANDPARTS-IN-PROGRESS GESTURAL - DEXTERITY
Fingers WORK STATION ADJUSTMENT - CONTROL
Knees VARIABILITY OF WORK ACTIVITY CONTROL OF APPEARANCE or CONFORMITY
Ankles ORGANISATION VIGILANCE
SYNTHESIS OF MAIN STAGE RATINGS Complexity rating
Designation and rating of main stages or main parts Effort rating
Posture rating P E C
OBSERVATIONS
Existence of a standard operation sheet (FOS): YES NO Conformity of observed operating mode with FOS: YES NO
Sheet completed by: Department: Date :
This form constitutes the reference for the evaluation of the work station constraints for all RENAULT sites throughout the world.
Copyright RENAULT S.A. Version 3 - 2002


POSTURE - EFFORT
CYCLICAL OR REGULAR ACTIVITIES
POSTURE EFFORT
N
DESCRIPTION OF THE MAIN STAGES
References Obs. FrEq. Duration Op, Real ReferenceWeighted Freq. Duration Op,
IN THE OPERATING MODE Level / h Level Effort Effort / h Level
Postures considered for a whole tack and not at each stage
Fittings and clips:
Movements in metres reported per minute:
Going up or down steps:
Stepping:

Max.
level
obs
Sumof
freqs
Sumof
duratio
ns
Station
rating
Average
effort
Sumof
freqs
Sum
of
duratio
ns
Station
rating
Effort : retain
the highest
rating value
OBSERVATIONS
Copyright RENAULT S.A.
The highest effort or the average the
most significant efforts
Average of all the efoorts superior to 1
kg


FREQUENT ACTIVITIES: non-cyclical, with a frequency from1 to 10x/h
Only complete this section if there are level 4 or 5 postures and/or efforts or weights >15 Kg
POSTURE EFFORT
DESCRIPTION OF OPERATIONS Reference Level Freq. Op, Real ReferenceWeighted Freq. Op,
Obs / h level level Effort / h level
Max.
level
obs
Sums of
freqs
Station
rating
Average
effort
Sums of
freqs
Station
rating
REGULATION
A : PROCESS B: ACTIVITY
WORK TEMPOS Fault VARIABILITY OF WORK ACTIVITY Fault
Frequencies or tack times Difficult supply or packaging 2
frequ./h # 67

Tcy $ 0,9 min
0 Positioning - Adjustment - Indexing None 0
67 < freq./h # 150 0,4 min # Tcy < 0,9 min
3 delicate or difficult Number 1 2
150 < freq./h # 300 0,2 min # Tcy < 0,4 min
6 of parts, assist devices, per cylce 2 3 4
freq./h > 300 Tcy < 0,2 min
9 equipment.... $ 4
6
Commitment # 95%
0 Alignment and bonding of parts With assembly fixture 2
Average random commitment. > 95% 100% 2 Without assembly fixture 4
Highest commitment in batches, > 100% 105% 6 Difficult removal of adhesive protections 3
except rare products > 105% 9 Blind work a low level of sensory dexterity 2
Random variation of time # 10%
0 Involving: a high level of sensory dexterity 3
Difference between min and max, > 10% 20% 3 the wearing of individual Conforms, but hinders gestural 2
according to diversity, > 20% 30% 6 protection equipment Unsuited to part of the activity 3
except rare products > 30% 9 Control, Setting, Adjustment
SPACE AND PARTS-IN-PROGRESS Occasional control of structural parts or parts with assembly fixture 2
Continual process, in stream Operator warning Systematic control of appearance - measuring or simple setting 3
or equivalent system Control with adjustment - setting with precision and interpretation 6
YES NO ORGANISATION
Regulation space YES 0 3 Overcrowding, with interference between operators 2
from 10 to 20 % NO 3 6 OTHER
Other processes: not free or parts-in-progress
Between each operator or group of operators
1 or 2 3 to 7 8 to 12 13 to 20 Sub-total B of the sum of factor faults .
operators operators operators operators
1 $ 2 $ 5 $ 10 0
STATION RATING
0 1 2 4 5 9 3
0 # + # 4 6 Grand System Subset
WORK STATION in full flow (unit, preparation module,
Dependence for execution of operating mode (fitting, painting, fitting line, etc.) stamping line, etc.)
No direct dependence on a means or other operators 0 Sub-total Sub-total B Sub-total Sub-total B
Dependence between operators for beginnings and ends of tack time 3 A 0-3 4-6 $ 7 A 0-3 4-8 $ 9
Dependence between operators during tack time (actions, movements) 4
Dependence on a means immediately upstream or downstreamof the sta 3
Dependence of the cycles of a technical means at the station 4
Insufficient space for the training assistance 3
Sub-total A of the sum of factor faults .
OBSERVATIONS
3
1 2 3
2
4
3
4
5
4
5
5

0 2

3 7

8 12

$ 13
3
1 2 3
2
4
3
4
5
4
5
5

0

1 4

5 8

$ 9


COMPLEXITY
FUNCTIONING Fault MODE OPERATOIRE dmrite
Size of batches (number of parts) $ 61
2 Number of main stages 3 4 2
* station indifferent to diversity 25 60 ou* 0 5 9 4
Retain the most disadvantageous batch, 7 24 3 $ 10
6
except rare products # 6
6 Number of operating modes 2 3 2
Random variation of time # 10%
0 according to the diversity of product/process $ 4
4
Difference between min and max, > 10% 20% 2
Operation rare: products rare < 5%of the volume of product.
5
according to diversity, > 20% 30% 3 ACCESSIBILITY - POSITIONING OF PARTS
except rare products
30%
6 Obliged to move the elements (interferences) 3
MACHINES - EQUIPMENT - TOOLS Accessibility difficult (lack of space, etc.) 3
Conduct of a complex machine or assist device 2 No centring device or indexing - delicate or difficult adjustment 3
Number of tools # 2
0 No location notch and risk of directional errors 3
3 4 2 Difficult wiring passage 3
5 9 3 Risks of warping of parts, of scratching or knocks 3
$ 10
6 Blind work with difficult positioning 3
Disposition and use of tools and equipment GESTURAL - DEXTERITY
Position at rest incoherent with operating mode 2 "Knack" particularly difficult to learn 2
Difficult access for positioning (lack of space, etc.) 2 Complex and/or decisive for quality or security 3
Visibility not good for positioning 3 Highly specific (masticking, painting, sanding, etc.) 5
Precision important for positioning (quality impact) 3 ADJUSTMENT - CONTROL
DIVERSITY OF PARTS AND FASTENINGS Simple control (assembly fixture, value reading, visible signal) 2
Parts Number of references Operation with interpretation of result (visual indexing, etc.) 3
2 4 5 9 $ 10
Complex op. and decisive for quality, CSR point 5
Parts encycled, in synchro or locked 0 0 0 CCONTROL OF APPEARANCE or CONFORMITY
Help for choice (visible, audible signal, etc.) 1 1 2 Implies continuous attention 3
No help, but easy differentiation 2 3 4 Very important for quality, without adjustment 4
No help and difficult differentiation 3 4 5 Important for quality, with adjustment 6
Fastenings Number of references VIGILANCE
2 4 5 9 $ 10
High sound environment 2
Parts encycled, in synchro or locked 0 0 0 Unsuitable lighting 2
Help for choice (visible, audible signal, etc.) 1 1 2 Unfavourable climatic or ventilation conditions 2
No help, but easy differentiation 2 3 4 Ejecta (soldering particles, dust, etc.) 2
No help and difficult differentiation 3 4 5 Use of sharp objects or chemical products 3
Recording of references on computer or list 2 Risks of jamming, blows, impacts or falling 3
SUPPLY - PACKAGING
Requiring particular attention as product quality risk 3 Sum of factor faults .
RATINGS
WORK STATION MAIN STAGES
Tack times or Sum of factor faults
Number of factors with a fault?$ 3
hourly frequency # , 6 9 10 13 14 18 19 23 24 28 $ )- 1 - 2 3 5 $ .
tcy $ 3 min
Level of
frq./h # 20
constraints
0,9 # tcy < 3 min
Main stages Rating
20 < frq./h # 67
0,2 # tcy < 0,9 min
67 < frq./h # 300
tcy < 0,2 min
frq./h > 300
Station constraint level
OBSERVATIONS

3

4

5 2
2 2 3 3 4 5
1 2 3 3 4 4 5
1
2 3 3 4 4 5 5
2 3 4 4 5 5 5



POSTURE
- Movements / mn
> 20 m
> 500 mm
- Going up or down:
- Stepping backwards >30% of
tack time
duration > 5 sec
HEAD
UPPER LIMB
Large
extension
backwards
or head
looking
$ 60
FINGER-HAND-
WRIST
No significant
flexion or
extension of the
hand
MOBILITY
OF LOWER
LIMBS
L
E
V
E
L
Dynamic position:
- Sitting-standing, or
- buttock rest
1
2
3
4
5
- Going up or down:
between operators
See table of
fittings and clips
- Static sitting position
- Standing with
possibilities of movement
(e.g.: on-board work
station)
See table of
fittings and clips
and clips
or
- Flexion or
extension of wrist
> 60 and effort
> 3Kg
articular complaint
- Movements / mn
between14 and20 m
- Going up or down:
empty,
operators
of tack time
duration of # 5 sec
See table of
fittings and clips
or
hand-forearm
- Considerable
screwing jolts
percussive tool
of wrist > 60
Head
looking
upwards
between 40
and 60 with
duration
> 5 sec or
rotation > 45
H2 k2
H1 k1
H3 k3
H4 k4
H5 k5
$ 60
0 to 10
or dorsal
support
$ 90 $ 60
BACK
$ 60
Without
upport or with
duration or
effort
- withupport (1)
or
- Duration# 2 sec
andeffort # 2 Kg
ROTATION
ANGLE
FLEXION
C1
No
rotation
10 30 30 60 20 40 10 30
(2) (2) (2) (2)
0 10 10 30
< 20 < 10
30 60 60 90
40 60
30 60
(2) (2) (2) (2)
B1 D1
B2 A2 D2 C2
B3 A3 D3 C3
B4 A4 D4 C4
B5 A5 D5 C5 E5
E4
- duration ( 5 sec
or
effort ( 2 kg
Armat
< 30
Hand under
Heart height
Arm at
< 30
- Duration # 5 sec
and
- effort # 2 Kg
Hand
above the
head
or
shoulder
raised
or
Armat
< 30
or
or
Hand at
heart height
ARM/HAND
Armat
30 to < 90
Hand at
shoulder height
Hand at
head height
Armat 90
or arm
outstretched
upwards
Hand at
heart height
Armat
30 to < 90
Hand at
shoulder height
Arm
60 at 90
or arms
outstretched
upwards
Hand
above the
head
Shoulder
raised
F2 G2
G1 F1
F3 G3
F4 G4
F5
Hand at head
height
Good
Bad
< 30 30 60 > 60
H2 H3 H4 # 3 Kg # 2 Kg
H3 H4 H5
> 3 6 Kg > 2 4 Kg
H4 H5 H5 > 6 10 Kg > 4 6 Kg
H5 H5 H5 ( 10 Kg ( 6 Kg
Flexion - Extension
of Hand
contact area
11 to 100x/h
or duration of
between 6
and 30% of
tack time
> 100x/h
or duration
> 30% of
tack time
1
2
3
4
5
# 10x/h or
duration #
5%of tack
time
3/4
(3)
4 5
4 3 2
1 2 3
2 1 1
1 1 1
Maximum
level
observed
Version 3 - 2002
(3) Rating
is # 6 kg
is > 6 kg
No
angle
POSTURE POSTURE
- Movements / mn
> 20 m
> 500 mm
- Going up or down:
- Stepping backwards >30% of
tack time
duration > 5 sec
HEAD
UPPER LIMB
Large
extension
backwards
or head
looking
$ 60
FINGER-HAND-
WRIST
No significant
flexion or
extension of the
hand
MOBILITY
OF LOWER
LIMBS
L
E
V
E
L
Dynamic position:
- Sitting-standing, or
- buttock rest
1
2
3
4
5
- Going up or down:
between operators
See table of
fittings and clips
- Static sitting position
- Standing with
possibilities of movement
(e.g.: on-board work
station)
See table of
fittings and clips
and clips
or
- Flexion or
extension of wrist
> 60 and effort
> 3Kg
articular complaint
- Movements / mn
between14 and20 m
- Going up or down:
empty,
operators
of tack time
duration of # 5 sec
See table of
fittings and clips
or
hand-forearm
- Considerable
screwing jolts
percussive tool
of wrist > 60
Head
looking
upwards
between 40
and 60 with
duration
> 5 sec or
rotation > 45
H2 H2 k2 k2
H1 H1 k1 k1
H3 H3 k3 k3
H4 H4 k4 k4
H5 H5 k5 k5
$ 60
0 to 10
or dorsal
support
$ 90 $ 60
BACK
$ 60
Without
upport or with
duration or
effort
- withupport (1)
or
- Duration# 2 sec
andeffort # 2 Kg
ROTATION
ANGLE
FLEXION
C1 C1
No
rotation
10 30 30 60 20 40 10 30
(2) (2) (2) (2)
0 10 10 30
< 20 < 10
30 60 60 90
40 60
30 60
(2) (2) (2) (2)
B1 B1 D1 D1
B2 B2 A2 A2 D2 D2 C2 C2
B3 B3 A3 A3 D3 D3 C3 C3
B4 B4 A4 A4 D4 D4 C4 C4
B5 B5 A5 A5 D5 D5 C5 C5 E5 E5
E4 E4
- duration ( 5 sec
or
effort ( 2 kg
Armat
< 30
Hand under
Heart height
Arm at
< 30
- Duration # 5 sec
and
- effort # 2 Kg
Hand
above the
head
or
shoulder
raised
or
Armat
< 30
or
or
Hand at
heart height
ARM/HAND
Armat
30 to < 90
Hand at
shoulder height
Hand at
head height
Armat 90
or arm
outstretched
upwards
Hand at
heart height
Armat
30 to < 90
Hand at
shoulder height
Arm
60 at 90
or arms
outstretched
upwards
Hand
above the
head
Shoulder
raised
F2 F2 G2 G2
G1 G1 F1 F1
F3 F3 G3 G3
F4 F4 G4 G4
F5 F5
Hand at head
height
Good
Bad
< 30 30 60 > 60 < 30 30 60 > 60
H2 H3 H4 # 3 Kg # 2 Kg
H3 H4 H5
> 3 6 Kg > 2 4 Kg
H4 H5 H5 > 6 10 Kg > 4 6 Kg
H5 H5 H5 ( 10 Kg ( 6 Kg
H2 H3 H4 # 3 Kg # 2 Kg
H3 H4 H5
> 3 6 Kg > 2 4 Kg
H4 H5 H5 > 6 10 Kg > 4 6 Kg
H5 H5 H5 ( 10 Kg ( 6 Kg
Flexion - Extension
of Hand
contact area
11 to 100x/h
or duration of
between 6
and 30% of
tack time
> 100x/h
or duration
> 30% of
tack time
1
2
3
4
5
# 10x/h or
duration #
5%of tack
time
3/4
(3)
4 5
4 3 2
1 2 3
2 1 1
1 1 1
Maximum
level
observed
Version 3 - 2002
(3) Rating
is # 6 kg
is > 6 kg
No
angle


EFFORT
Holding
time
(% of tack
time)
Frequency
of repetition
per hour
# 5% # 10
Efforts or weight (Kg)
21
# 30%
6
# 10%
11
# 20%
31
# 40%
61
# 80%
91
100%
11
# 30
31
# 67
68
# 120
121
# 190
291
# 490
$ 721
81
# 90%
491
# 720
41
# 60%
191
# 290
(1 to
2
( 2 to
4
( 4 to
6
( 6 to
9
( 9 to
12
(12 to
15
(15 to
20
()* to
25
( 25
1 1
1
2 2
2 2
2 2
3 3 4
3
3
3
3
3
2
3
3
3
3 3
3 3
4
4 4
4
4
4
4
4
4
4
4 2
4
5
5
5 5
5 5
5 5
5 5
4 4 5 5
5 5
3 3 4 4 5 5
#+
1
1
1
3
2
3
1
3
2
COEFFICIENTS OF WEIGHTINGS OF THE EFFORTS OR THE WEIGHT
0,5
0,5
0,7
1,5
1,5
1,5
1,5
1,5
1,5
1,5
1,5
2
2
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
CALCULATION RULE
unfavourablerating:
carrying the load.
Note:
Rule for using weightings. The weightings only apply for loads > 2 kg. When a weighting applies, multiply the effort of the measured weight by the
coefficient to determine the weighted effort or weight to be reported in the "weighted effort" column of the "description of main stages" grid. In the same grid,
indicate the reference (e.g. P5) in the appropriate column. For weightings P4 to P11, if two or more weightings apply simultaneously to the same load
handling operation, apply a coefficient of 2. Exceptionally, andafter validation by an expert, it is possible to integrate particular conditions which do not figure
in the present table.
Rule for measuring efforts. For efforts effected with a resistance to initial movement of the object (trolley, assist device, etc.), the average effort should
be measured as follows: [initial effort + effort in movement] / 2, or [initial effort + effort in movement + stopping effort] / 3.
Notably for initial effort, it is recommended to simulate as closely as possible the real work conditions and to have the measurement taken by several
people.
Fitting and clipping efforts. These efforts are only taken into account with the "posture" criterion as the risks are mainly peri-articular.
Efforts above 15 kg, effected less than once an hour. Do not integrate in the station rating, but note them in the observation box, unless there is a
risk by association with a painful posture.
*Bulky part. This is a part with one value (height, width or depth) greater than 1,000 mm, not including light and flexible parts (cables, flexible tubs, etc.).
EFFORT
Holding
time
(% of tack
time)
Frequency
of repetition
per hour
# 5% # 10
Efforts or weight (Kg)
21
# 30%
6
# 10%
11
# 20%
31
# 40%
61
# 80%
91
100%
11
# 30
31
# 67
68
# 120
121
# 190
291
# 490
$ 721
81
# 90%
491
# 720
41
# 60%
191
# 290
(1 to
2
( 2 to
4
( 4 to
6
( 6 to
9
( 9 to
12
(12 to
15
(15 to
20
()* to
25
( 25
1 1
1
2 2
2 2
2 2
3 3 4
3
3
3
3
3
2
3
3
3
3 3
3 3
4
4 4
4
4
4
4
4
4
4
4 2
4
5
5
5 5
5 5
5 5
5 5
4 4 5 5
5 5
3 3 4 4 5 5
#+
1
1
1
3
2
3
1
3
2
COEFFICIENTS OF WEIGHTINGS OF THE EFFORTS OR THE WEIGHT
0,5
0,5
0,7
1,5
1,5
1,5
1,5
1,5
1,5
1,5
1,5
2
2
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
CALCULATION RULE
unfavourablerating:
carrying the load.
Note:
Rule for using weightings. The weightings only apply for loads > 2 kg. When a weighting applies, multiply the effort of the measured weight by the
coefficient to determine the weighted effort or weight to be reported in the "weighted effort" column of the "description of main stages" grid. In the same grid,
indicate the reference (e.g. P5) in the appropriate column. For weightings P4 to P11, if two or more weightings apply simultaneously to the same load
handling operation, apply a coefficient of 2. Exceptionally, andafter validation by an expert, it is possible to integrate particular conditions which do not figure
in the present table.
Rule for measuring efforts. For efforts effected with a resistance to initial movement of the object (trolley, assist device, etc.), the average effort should
be measured as follows: [initial effort + effort in movement] / 2, or [initial effort + effort in movement + stopping effort] / 3.
Notably for initial effort, it is recommended to simulate as closely as possible the real work conditions and to have the measurement taken by several
people.
Fitting and clipping efforts. These efforts are only taken into account with the "posture" criterion as the risks are mainly peri-articular.
Efforts above 15 kg, effected less than once an hour. Do not integrate in the station rating, but note them in the observation box, unless there is a
risk by association with a painful posture.
*Bulky part. This is a part with one value (height, width or depth) greater than 1,000 mm, not including light and flexible parts (cables, flexible tubs, etc.).

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RENAULT 2002 Origin: PEGI Renault Page: 1 / 55

Guide of help of the Ergonomics of

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