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ACUPATH iLMM Operators Manual

OPERATORS
MANUAL
for

with

2.4
SOFTWARE

Biodynamic Solutions, Inc

ACUPATH iLMM Operators Manual


Copyrights, Patents and Trademarks
U.S. Patents 5,143,088 and 5,012,819
BALLET 2.4 Software is based on Lumbar ProSoft Software
Lumbar ProSoft Software copyright 1999, 2000, 2001, 2011
Biodynamic Solutions, Inc. All rights reserved.

Part Number 0300-000005-1.1


Revised: 09/01/2011
Printed: 09/02/2011
Biodynamic Solutions, Inc
330 W Spring St, Suite 205
Columbus, OH 43215

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ACUPATH iLMM Operators Manual

Table of Contents
Safety ......................................................................................................................................................... 1
Chapter 1 - Introduction ......................................................................................................................... 2
Chapter 2 - Hardware Installation and Set Up ..................................................................................... 4
Recommended Equipment ..................................................................................................................... 4
Checking the Parts List & Identifying Components .............................................................................. 5
Unpacking and Repacking the iLMM .................................................................................................... 5
Setting Up the ACUPATH iLMM System for Data Collection ................................................... 8
Configuring the iLMM Hardware ...................................................................................................... 8
Setting Up the iLMM Device ............................................................................................................ 9
Fitting the iLMM Device to the Employee ...................................................................................... 10
Chapter 3 - BALLET 2.4 Software Operation .............................................................................. 133
Introduction ........................................................................................................................................ 133
BALLET 2.4 Software Highlights: .................................................................................................... 133
System Requirements ......................................................................................................................... 133
Installing the BALLET 2.4 Software ................................................................................................. 144
Starting the BALLET 2.4 Software ................................................................................................... 144
Overview of BALLET Software ........................................................................................................ 144
Start-up Screen ............................................................................................................................... 144
Menu Items .................................................................................................................................... 146
Database Hierarchical Structure .................................................................................................... 200
Data Editing of Trials and Analysis Set Up ................................................................................... 222
Setting Up the Hierarchical Structure .................................................................................................. 25
Project .............................................................................................................................................. 25
Company .......................................................................................................................................... 25
Job .................................................................................................................................................... 26
Task .................................................................................................................................................. 26
Employee ....................................................................................................................................... 322
Collecting Data .................................................................................................................................. 334
Adjusting iLMM Offsets ................................................................................................................ 344
Collecting Data .............................................................................................................................. 355
Viewing Data ....................................................................................................................................... 37
Analyzing Data .................................................................................................................................... 39
Chapter 4 - Using the ACUPATH iLMM and LBD Risk Model ........................................... 444
Selecting the Job(s) to Monitor .......................................................................................................... 444
Defining the Major Job Components through a Task Analysis ......................................................... 455
Collecting and Recording Workplace Data for Risk Assessment ..................................................... 466
Collecting the Data .............................................................................................................................. 47

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ACUPATH iLMM Operators Manual


Chapter 5 - Analyzing and Interpreting the Data .............................................................................. 49
Interpreting Results from Several Employees ................................................................................... 522
Approaches to Intervention ................................................................................................................ 522
Chapter 6 - Maintenance ..................................................................................................................... 556
Battery Charging ................................................................................................................................ 556
iLMM and Cable Care ....................................................................................................................... 556
Chapter 7 - Reference ............................................................................................................................ 57
Troubleshooting ................................................................................................................................... 57
Technical Support ................................................................................................................................ 58
Accessories, Supplies and Services ..................................................................................................... 59
End-User License Agreement ............................................................................................................ 600
Limited Warranty ............................................................................................................................... 622
Index .................................................................................................................................................. 623

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ACUPATH iLMM Operators Manual

Safety
Note: Read this entire section BEFORE proceeding to install, connect, operate or
service the ACUPATH iLMM or BALLET 2.4 Software
WARNING! Never connect or disconnect the power cable when the system is on; user injury or
product damage may result.
WARNING! Never handle a live connector. Connect all the cables before plugging the system into a
wall outlet.
WARNING! Do not cut-off or bypass any grounding prongs or other safety features.
WARNING! Do not use in the presence of flammable anesthetics or other flammable gases or liquids.
Explosion may result.
Caution:

Do not attempt to service this product yourself as risk of injury and/or product damage
may result. There are no user serviceable parts inside of the product. The products
warranty will be void if unauthorized repairs or alterations are conducted on any part of
this product. Use only authorized replacement parts or components.

Caution:

Allow the case to adjust to room temperature before unpacking components. Unpacking
a cold system and exposing it to a warm environment may cause condensation to form.
Never connect the system until moisture from condensation has completely dried, or
damage may result.

Caution:

This product is a sensitive mechanical device. Any damage caused by mishandling the
product, failure to follow all operating instructions, or failure to follow recommended
preventative maintenance procedures may result in inappropriate output from the device.
If product damage is suspected: (1) do not operate the product; and (2) contact the
manufacturer to arrange for product repair.

Caution:

Do not place food or beverages on or near any product components.

Caution:

This product has an ordinary degree of protection against the ingress of water or other
liquids. Do not submerge any part of this product in water.

Note:

Be sure that all people operating this product read and understand these instructions prior
to using the system.

Note:

Keep this Operators Manual available for users of the system to read and refer to at all
times.

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Chapter 1 Introduction
Low back disorders (LBDs) are among the most common occupationally related injuries, which affect
an estimated 80% of the population at some time during their working careers. Prior to the
ACUPATH Industrial Lumbar Motion Monitor (iLMM), the tools available to evaluate LBD Risk
in industrial jobs were limited in their ability to account for the impact of dynamic movements. The
iLMM provides a practical method of assessing the dynamic trunk motions required of materials
handling tasks in industrial settings.
The patented iLMM is a tri-axial thoracolumbar goniometer that tracks motion of the lumbar spine.
This is accomplished by having an employee wear one harness across the upper body and a second
around the pelvis. Sensors attached to each harness are positioned on ones back, directly in line with
the spine. The sensors measure their positions relative to one another, in three-dimensional space, as an
employee performs a task. Position data from the sensors are recorded at 60 Hz and then transmitted to
and recorded on a notebook computer. The data are then processed to calculate the spines threedimensional position, velocity, and acceleration during the data collection period. Using an iLMM, one
can measure the specific ranges of motion, velocities, and accelerations of the lumbar spine as
employees perform their job tasks. The iLMM also allows one to compare the trunk motions required of
a task to a normative database of jobs that were previously found to have a high incidence of LBDs
among employees. These comparisons, combined with the data from a job site assessment, comprise a
model that determines the level of LBD Risk associated with the task and provides the basis for
recommending ergonomics improvements, if needed.
Use of the iLMM and the LBD Risk model provides several advantages for one studying injury risk of
manual materials handling (MMH) activities:

The iLMM allows for the determination of an instantaneous, three-dimensional position of the
trunk while employees perform their actual job tasks, not work simulated in a laboratory. This
eliminates the question of whether a MMH study conducted in an artificial setting can be
generalized to the workplace. In addition, the iLMM data are gathered objectively. Resulting
calculations of LBD Risk are free from an investigator's (perhaps unintentionally biased) view of
the work.
Materials handling jobs can be assessed relative to a large database that includes jobs from
diverse manufacturing environments and with different levels of LBD Risk. This enables the
investigator to determine if a job has a high probability of injuring employees who perform that
job. It also allows one to rank several jobs, based on their risk values, and focus on solutions for
those jobs that have the greatest chance of producing LBDs.
The LBD risk model provides a quantitative assessment and comparison of each task within a
job. Specific factors that contribute to a task's risk level are identified, as are the tasks that
contribute most to the job's overall risk. This information pinpoints the specific tasks and the
factors therein that must be addressed during a job redesign to reduce its injury risk potential.
This quantitative assessment also permits the investigator to make decisions about what level of
risk is acceptable for a MMH job. While it is not possible to totally reduce a jobs risk to zero,
the LBD Risk model allows for comparison of a jobs risk with the criteria of acceptance set by
the company.

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The LBD risk model assists in the ergonomics intervention process. Modified jobs can be remonitored using the iLMM, and the effects of the changes can be quantified and compared with
the values determined prior to the intervention. Traditionally, the effects of job changes on the
numbers of related musculoskeletal strains (e.g., the job's incident rate) may take several years to
appear. The iLMM can produce much more timely feedback regarding anticipated returns on the
redesign investment. For jobs that produce minimal reductions in risk due to redesign efforts,
further improvements can be attempted sooner. In other words, this risk model can assist in
determining whether or not an ergonomic intervention has produced enough of an improvement
in a job to justify such a change.

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ACUPATH iLMM Operators Manual

Chapter 2 Hardware Installation and Set Up


Recommended Equipment
ITEM
ACUPATH Industrial
Lumbar Motion
Monitor, in Storage/
Shipping/Field Desk Case

DESCRIPTION
Computer Tray
Space for notebook computer with
BALLET 2.4 software (on CD)
Operators Manual
USB radio, with 5 ft USB cable
Radio repositioning plate
AA battery charger, with power cord
Rechargeable AA batteries (4)
Shipping case lock key (2)
Device Tray
iLMM upper and lower components
and radio, on storage plate
iLMM cable connector
USB-to-LMM cable
Rechargeable batteries (4)

Scale
(heavy duty; minimum
1-100 lb range)
Push/Pull Gauge
(minimum 1-100 lb range)
Tape Measure

Extension Cord
(grounded, minimum 50 ft)
Outlet Strip/
Surge Suppressor
Wheeled Cart
Notebook and Data
Collection Forms

Case Bottom
Shoulder harness
Waist belt
30 ft USB extension cable
For measuring weights of objects handled by
employees during job tasks.
For measuring the forces pushed or pulled by
employees on an object.
For measuring the horizontal distance objects
are held from the spine during job tasks. Also
useful for measuring vertical work heights,
the sizes of objects handled, and other
relevant workplace dimensions.
For connecting to remote power outlets.
For recharging batteries and powering other
electronic devices used in a job evaluation,
such as cameras and video recorders.
Accessory data collection equipment storage.
For recording information, comments and
relevant information about the job.

WHERE TO OBTAIN
All hardware, except
computer and
accessories, is supplied
by Biodynamic Solutions,
Inc
Notebook computer can
be purchased from a
commercial computer
retailer.
BALLET 2.4 software
is included with the
iLMM.

Commercially available.

Commercially available.
Commercially available.

Commercially available.
Commercially available.

Commercially available.
Commercially available.

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Checking the Parts List & Identifying Components


An inventory of the iLMM components should be conducted and compared with recommended
equipment list on page 4. Any missing items should be reported to NexGen Ergonomics Inc. See
Chapter 7 for Technical Support.

Unpacking and Repacking the iLMM


The iLMM is stored within a
durable, wheeled case for shipping
and easy transport. It has three
storage compartments; the case
bottom; a removable computer tray;
and a removable device tray.

Shoulder Harness

The case bottom stores the shoulder


harness, waist belt, and 30 ft data
cable, as shown in Figure 1a.
The computer tray (Figure 1b)
contains an Operators Manual,
software CD, the USB radio (with
attached 5 ft cable), a radio repositioning plate, AA battery charger
(w/power cord), four rechargeable
AA batteries, two case lock keys,
and space for a notebook computer.
The device tray holds the threepiece iLMM (upper component,
lower component, and radio)
secured to a zero-plate, four
rechargeable AA batteries, a cable
to connect the upper and lower
iLMM components, and a cable to
connect the iLMM directly into a
computers USB slot. These items
are shown in Figure 1c.
Both trays contain compartments
for keeping items securely in place
during iLMM use or case transport.
Additional compartments are provided to store miscellaneous equipment and supplies. The trays can
be placed into the case in either
order.

W aist Belt

30ft USB Extension Cable

Figure 1a. Case with components stored in bottom.


Software USB Radio, with Rechargeable
CD
5 ft USB Cable AA Batteries

Shipping Case
Lock Keys

Operators
Manual
(not shown)

Space for
Computer

AA Battery Charger,
with Power Cord

Radio
Repositioning Plate

Figure 1b. Computer tray.

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The bottom of each tray contains
two slots. These can be used to set
the tray on top of the upright, closed
case, providing the user with a stable
field desk work surface (see
Figure 2a).

AC UP ATH iLM M T M
C ompone nts a nd R adio

Once packed, a handle can be


extended from the case, by
depressing the red button located
near the handle (Figure 2b). A
click will be heard when the
handle is pulled to its maximum
length. The button must be
depressed to either extend the handle
or to store it back within the case.
Connecting and Disconnecting the
iLMM Lower Component and
Radio

Re char gea ble B a tte ries USB -to- LM M iLM M C able


( not visible )
Ca ble
Conne ctor

Figure 1c. Device tray.

The radio (identified by the red


on/off button) attaches to the lower
iLMM component, as shown in
Figure 3a. With the radios
connector facing the lower iLMM
component, move the radio between
the components two guides until the
radios connector snaps into place.
There will be an audible click that
indicates the two units are properly
connected.
To separate the two units, depress
the radio connectors tab and slide it
away from the iLMM lower
component (see Figure 3b).

AC UPA TH iLM M T M
S torage P late

a.

b.

Figure 2. Field desk work surface and pull handle operation.

Note: NEVER force the radio on or off the iLMM component. These two units should slide easily
together and apart.
Inserting and Removing Radio Batteries
The radio is equipped with two sets of (four) rechargeable AA batteries. To insert batteries, locate the
battery slot on the bottom of the radio. Depress the slot cover and slide it in the direction of the arrow
(see Figure 4a), and remove the battery housing contained inside. Place four charged batteries into the
housing, in the orientation identified on the housing (Figure 4b). Then place the batteries and housing
back into the radio slot, and make sure that no wires are protruding from the unit (Figure 4c). To secure

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the batteries and housing, replace the
slot cover in the reverse manner that
it was removed (see Figure 4d).
Note: Non-rechargeable AA batteries can also be used in the iLMM.
Removing the iLMM from the
Device Tray and Storage Plate
Unscrew the knurled (textured) nuts
from the threaded studs that secure
a.
b.
the iLMM upper component to the
Figure 3. Connecting the radio to the iLMM lower
storage plate (Figure 5a). Do the
component (a.) and disconnecting the two units (b.)
same for the lower component/radio
(Figure 5b). Each component can
then be taken off the storage plate (Figure 5c). The iLMM can be remounted onto the storage plate by
reversing these instructions.

a.

b.
a.

c.

d.

Figure 4. Inserting/removing radio batteries:


slide open the slot cover (a.), put
batteries into housing (b.), reinsert
housing (c.), and replace cover (d.) .

b.

c.
Figure 5. Loosening the upper (a.) and lower
component (b.) of the iLMM from
the storage plate and removing it (c.)
from the device tray.

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Setting Up the ACUPATH iLMM System for Data


Collection
Configuring the iLMM Hardware
The iLMM can be configured in three ways:
1. The radio telemetry configuration (Figure 6a) allows the employee wearing the iLMM to work
completely un-tethered to the data collection computer, since the transmission system is contained
within the iLMM.
2. The mobile telemetry configuration (Figure 6b) allows both the iLMM wearer and the system
operator to work un-tethered, when data collection occurs using a notebook computer on battery
power. This is very useful when operating the system in remote or unpowered settings.
3. The hardware configuration (Figure 6c) can be used when tethering the iLMM wearer to the
computer does not impact the data collection process. The iLMM will automatically sense the
communication setup and operate accordingly.

Figure 6a. iLMM telemetry configuration.


Note: For the two telemetry configurations, the USB radio will:
Blink RED if there is no power to the iLMM;
Blink GREEN (the light on 50% of the time) if there is power to the iLMM but no data are being
transmitted; and
Blink GREEN (the light on 90% of the time) if there is power to the iLMM and data are being
transmitted.
Note: The USB radio has four suction cups attached to it. This will allow the system user to reposition
this radio on a smooth, dry surface, if necessary, to aid in signal transmission. The computer tray also
contains a radio repositioning plate that, when attached to the USB radio, provides further flexibility in
positioning it for increased signal transmission.
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Figure 6b. iLMM mobile telemetry configuration.

Figure 6c. iLMM hardwired configuration.

Setting-up the iLMM Device


Checking Signal Accuracy of the iLMM
During normal usage of the iLMM, this radio transmission signal may change slightly. Thus, it is
important to periodically check that accurate readings are being transmitted and recorded.
To check or readjust the iLMM signal, first make certain that its upper and lower components and radio
are secured onto its storage plate in the device tray, using the knurled/textured nuts supplied with the
unit (see Figure 3). Position the unit (i.e., iLMM, storage plate, and device tray) so that it is not
horizontal before conducting the signal check (see Figure 7). Then turn the unit on, by pushing the
radios red toggle switch.

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Note: NEVER check or readjust the iLMM when it is lying
horizontally.
Use the radio telemetry (or attach the USB cable from the iLMM
to the computer), and check the iLMM position values using the
supplied BALLET 2.4 software. Readings in all three motion
planes (lateral, sagittal, twisting) should be at or near 0 deg.
Remove the upper component of the iLMM from the device tray
and move it in different positions above the lower component/
radio. The three traces on the computer screen should show
realistic position values. If the traces do not show realistic
position values, check that the upper component is within six
inches of the lower component.
Fitting the iLMM Device to the Employee
The iLMM is a one-size-fits-all device. Regardless of the height
or spine length of the employee wearing the monitor, the iLMM
automatically adjusts to provide accurate trunk kinematic data.
After it has been confirmed that the iLMM is transmitting
accurate readings, it is ready to be placed on an employee.
Attaching the iLMM Upper Component to the Shoulder
Harness. To remove the iLMM upper component from its
storage plate, unscrew the four knurled (textured) nuts from the
threaded studs that secure it to the storage plate, and lift it off
vertically, as shown in Figure 5a. With the shoulder harness
(Figure 8) lying flat, remove the nuts from the four threaded
studs located in the center of this harness. Then place the iLMM
upper component onto these studs in the same orientation it was
originally positioned on its storage plate (see Figure 7). Ensure
that each stud has extended through this upper component, and
use the nuts to secure it to the harness.

Figure 7.

Orientation of the
device tray to check
the signal accuracy of
the iLMM.

Figure 8.

Shoulder harness for


the iLMM.

Note: The iLMM upper component is properly positioned on the shoulder harness when the slot
for the iLMM cable connector is facing down.
Placing the Shoulder Harness / iLMM Upper Component on the Employee. The padded iLMM
shoulder harness (Figure 8) is attached to straps using metal D-rings. These straps can be identified by a
green and a red patch on the left and right sides on the hook-and-loop straps, respectively. These hookand-loop straps are adjustable in that the unneeded length can be secured to itself when used on smaller
employees or lengthened when placing it on larger employees. The hook-and-loop straps attached to the
lower part of the shoulder harness (marked with a yellow patch) fit horizontally across the employees
midsection and can be adjusted in the same manner as those placed over the shoulders.
The shoulder harness is to be put on the employee in a cross-your-heart style configuration. To
properly position the shoulder harness, follow these steps:
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ACUPATH iLMM Operators Manual


1. Ensure the harness is oriented so that the upper shoulder pads are curved toward each other, as
shown in Figure 8.
2. Place the upper part of the harness over the shoulders (Figure 9a), and ask the employee or an
assistant to keep it in place. The iLMM upper component should be located approximately between
the shoulder blades (Figure 9b), not against the upper back.
3. Move around to face the employee, and connect the hook-and-loop straps on the upper part of the
shoulder harness to their color-corresponding lower straps (Figure 9c). The amount of harness
overlap should be the same over both the right and left shoulders.
4. Connect the hook-and-loop straps at the bottom of the shoulder harness, which can be identified by
their yellow patches (see Figure 9d.).
5. The shoulder harness is properly placed when it fits snugly on the employee but still enables him/her
to breathe normally.
Note: Data quality will be affected if the iLMM upper component (on the shoulder harness) is not
oriented vertically. Ensure that the iLMM upper component is placed between the shoulder
blades rather against the upper back.

a.

b.

c.

d.

Figure 9. Fitting the shoulder harness in the cross-your-heart style configuration. Place
harness against the employees back (a.) and between the shoulder blades (b.). Adjust the
straps using the red, green, and yellow color codes (c. and d.).
Attaching the iLMM Lower Component / Radio to the Waist Belt. To remove the iLMMs lower
component, unscrew the four nuts from the storage plates threaded studs (see Figure 5b); then lift the
unit off vertically. With the waist belt (Figure 10) lying flat and the
threaded studs facing up, remove the four nuts. Place the iLMM lower
component over these studs in the same orientation it was positioned on
its storage plate (see Figure 7). After ensuring that each stud has
extended through the holes in the base of the lower component, secure it
to the belt using the nuts.

Figure 10. Waist belt for


the iLMM.
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ACUPATH iLMM Operators Manual

a.

b.

c.

d.

Figure 11. Putting the iLMM on the employee. Align the waist belt and iLMM lower
component with the spine and at the top of the employees hips (a.). Momentarily secure the
belt using its hook-and-look strap (b.). Make sure the iLMM is fitted correctly (c.). Secure the
waist belts leg straps (d.).
Placing the Waist Belt / iLMM Lower Component / Radio on the Employee. With the employee
standing upright, fit the waist belt and iLMM components (Figure 11a) around the hips and momentarily
secure them with the belts hook-and-loop strap (see Figure 11b). The top of the iLMM lower
component should be in line with the trunks lumbo-sacral joint (L5/S1). This position can be attained by
locating the top of the employees hips (the iliac crest) with the fingers and aligning the top of the waist
belt with this position on the employee. The curved design of the waist belt (see Figure 10) positions the
iLMM/ lower component/radio at the L5/S1 joint. See Figure 11c for proper iLMM alignment on an
employee.
When the iLMM lower component/radio has been positioned, check that the upper and lower
components of the iLMM are aligned vertically, just as they when on their storage plate. If not, one or
both of the following adjustments can be made:
The waist belt can be moved to the left or right.
The shoulder harness can be loosened and adjusted by re-tightening the hook-and-loop straps
connected to the shoulder harness.
Once the iLMM is properly positioned, securely tighten the hook-and-loop strap on the waist belt
(Figure 11b). Then bring each leg strap between the legs of the employee and insert into the clasps on
the right and left sides of the waist belt (see Figure 11d). It is important to always use these leg straps,
which prevents the iLMM from moving around on the hips. A significant shift of the waist belt during
use of the iLMM will result in erroneous data.
Note: It is important to check for proper alignment of the iLMM after any readjustment or straptightening has occurred.

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ACUPATH iLMM Operators Manual

Chapter 3 BALLET 2.4 Software Operation


Introduction
This chapter describes the BALLET 2.4 data collection and analysis software that accompanies the
iLMM. It describes how to install, start-up, navigate through, and use the software to collect valid trunk
kinematic data and obtain an accurate low back disorder (LBD) risk analysis.
The iLMM data collection system parcels out the work being analyzed into individual job tasks, so that
specific ranges of motion, velocities, and accelerations of the lumbar spine can be determined. It allows
one to compare the tasks of interest with a (previously gathered) normative database of workplace
variables associated with MMH jobs found to have a high incidence of LBDs. These comparisons,
combined with the data from the job site assessment, allow the user to assess the risk level of a task. It
also guides the formulation of any needed ergonomics-related changes.

BALLET 2.4 Software Highlights

Easy and intuitive navigation. "Hot buttons" assist the user in software functionality and navigation.

Operation using a mouse, keystrokes, and keyboard Function keys.

Audio feedback that alerts user to iLMM signal interference.

Improved data exporting capabilities using Microsoft Access format. The user can export both
summary trunk motion statistics across a series of similar activities, as well as instantaneous trunk
motion data for a particular set of data.

An LBD Risk analysis can be calculated for each job subtask of interest, as well as for a job that is
comprised of several job subtasks.

An averaged LBD Risk value can be assessed across multiple employees performing the same job or
job subtask.

Jobs can be assessed using both the 1981 and 1991 equations from the NIOSH Work Practices
Guide for Manual Lifting, as well as through the use of previously published psychological tables for
lifting, lowering, pushing, pulling, and carrying tasks.

Warnings and alert messages prevent the user from making errors during data collection and
analysis, such as iLMM signal quality degradation of if the recommended number of trials needed
for an LBD risk assessment has not been gathered.

The user controls data collection beginning and ending times, which is necessary for tasks with
varying cycle times.

System Requirements
A PC computer with a Windows 95, 98, XP, NT, or 7 operating system and a CD-ROM is required to
operate the BALLET 2.4 software. A minimum 133 MHz Pentium with 16 MB of RAM (32 MB
recommended) is required. A notebook computer is recommended for field use.
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ACUPATH iLMM Operators Manual

Installing the BALLET 2.4 Software


To install the BALLET 2.4 software, follow these steps:
(1) Insert the BALLET 2.4 Installation CD into your computers CD-ROM drive. This will cause an
AutoPlay dialog box to appear.
(2) Select "Run setup.exe" from the AutoPlay dialog box options. This will initiate the Industrial
LMM Software 2.4 Setup
(3) Follow the screen prompts to complete the installation.

Starting the BALLET 2.4 Software


To start the BALLET 2.4 software, click on the Windows Start menu, then click All Programs. From
the list of your computers loaded software, click on the "Ballet 2.4" folder. The program file Ballet
2.4 will be listed. Click on this file to load the software.

Overview of BALLET Software


Start-Up Screen
The BALLET 2.4 Start-Up Screen is divided into three functional areas, as shown in Figure 12: the
navigation menus and hot buttons; the hierarchical structure of the database; and the data entry screen.
The navigation menus and hot buttons allow the user to set up the data collection structure, as well
as collect and analyze workplace and iLMM data.
The hierarchical structure of the database provides an organized way of establishing and reviewing
data.
The data entry screen allows for the input of company, job, task, employee and other workplace data
and information.

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Hierarchical Structure

Navigation Menu

Hot Buttons

Data Entry Screen

Figure 12. BALLET 2.4 initial screen.

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Menu Items
The BALLET 2.4 software contains File, Edit, Options, and Project pull-down menus, as described
below.

File Menu Pull-Down Options

Open Project
Close Project
Exit

A NEW PROJECT allows the user to name a new data file and begin building the
hierarchical structure for iLMM data collection and workplace analysis. A
PROJECT consists of a COMPANY name, the JOBS and individual job TASKS
that make up each job of interest, and the EMPLOYEE(s) that are to be monitored.
A PROJECT can consist of data from just one COMPANY, the same COMPANY
but different site locations, or for multiple visits or data collection sessions.
Opens an previously established PROJECT.
Closes an open PROJECT.
Exits the BALLET 2.4 software.

Undo

Undoes the last keyboard function.

New Project

Edit Menu Pull-Down Option


Options Menu Pull-Down Options
Toolbar
Status Bar
Settings

Adjust
iLMM
Offsets

Psychophysical

The toolbar option appears before a PROJECT is defined or opened. Checking the toolbar
option shows the New Project and Open Project Icons.
The status bar option appears before a PROJECT is defined or opened. Checking the
status bar displays the current date and time on the BALLET 2.4 screen.
Allows the user to select which COMM PORT is to be used during BIOMEC iLMM data
collection with either the telemetry or cable option. When using the iLMM3, the LMM3
setting will be selected automatically.
Permits the DISPLAY UNITS (Metric or English) to be chosen, for later keyboard data
entries (e.g., Load Weight, Lifting Frequency).
When using the iLMM3: No offset adjustment is needed. However, this option can be
used as a check that the motion traces are reading as expected.
When using the BIOMEC ACUPATH iLMM: Adjusts the iLMM potentiometers to
zero before use. Before the iLMM is adjusted, the data collection parameters must be
identified (company, job, tasks, and employee). Adjustments of iLMM Offsets must be
performed before collecting trunk motion data on each employee.
Performs a psychophysical analysis on a material handling activity, using published
psychophysical tables for maximum acceptable weights and forces. (See SH Snook and
VM Ciriello, The design of manual handling tasks: revised tables of maximum acceptable
weights and forces, Ergonomics, 34(9):1197-1213, 1991, for further information on the
psychophysical approach.) This analysis is a stand-alone module and is not linked to the
iLMM database of MMH activities and input parameters. See Section 3 to perform a
psychophysical analysis for MMH activities utilizing inputs from the BALLET 2.4
database.

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Options Menu Pull-Down Options
NIOSH

1981

1991

Export
Summary
Data

These two options are for computing safe lifting limits, using equations developed by the
National Institute for Occupational Safety and Health in 1981 (Work Practices Guide for
Manual Materials Handling, DHHS (NIOSH) Publication No. 81-122, 1981) and 1991
(Applications Manual for the Revised NIOSH Lifting Equation, DHHS (NIOSH)
Publication No. 94-110, 1994).
Calculates 1981 equation. The necessary input data are: horizontal hand locations at the
beginning and end of the lift; vertical hand heights at the lift origin and destination;
frequency of the lifting task; and duration over which the lifting occurs. This analysis is a
stand-alone module; it is not linked to the iLMM database of MMH activities and input
parameters.
Computes the 1991 revised equation. Needed input data are: weight of the object lifted;
horizontal hand locations at the beginning and end of the lift; vertical hand heights at the
lift origin and destination; asymmetry (i.e., amount of trunk twisting) required during the
activity; frequency of the lifting task; duration over which the lifting occurs; and the level
of hand/object coupling. This stand-alone analysis module it is not linked to the iLMM
database of MMH activities and input parameters.
Outputs time-dependent trunk motion and workplace data into a text-formatted file, useful
for additional data processing and analyses. All data are exported in metric units.
Data calculated across each trial of data collected. Data can be exported by:
Job (i.e., all trials gathered across every task and employee who performed those tasks
within the selected job);
Task (i.e., all trials across every employees who performed the chosen task);
Job/Employee (i.e., all trials for every task the chosen employee performed); and
Employee/Task (i.e., all trials performed by the selected employee and job task.
Every trial collected is initially highlighted, so that all data will be exported into a
common text-based file. Any individual trials that the user does not wish to be exported
can be deselected.
Identification
Company
Run Date
Data
Job Name
Run Number
Last Name
Task Name
First Name
Trial Number
Middle Name
Gender
LBD Risk
Load Weight
Moment Arm at Origin
Model Data
LBD Lift Rate
Moment Arm at Destination
Frequency per Minute

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Options Menu Pull-Down Options
Trunk Motion
Data

NIOSH
1981 & 1991
Lifting
Equations

Psychophysical
Data

Motion
Data

Identification
Data

Instantaneous
Trunk Motion
Data

Maximum Left Bend


Maximum Right Bend
Maximum Lateral Range
Maximum Extension
Maximum Flexion
Maximum Sagittal Range
Maximum Left Twist
Maximum Right Twist
Maximum Twisting Angle
Vertical Start Height
Vertical End Height
Asymmetry at Origin
Asymmetry at Destination
Duration
Frequency per Minute
Coupling
Activity
Frequency
Lift/Lower Location
Object Depth
Vertical Travel Distance
Push/Pull/Carry Distance
Push/Pull/Carry Height
Max. Weight 90th Percentile
Max. Weight 75th Percentile
Max. Weight 50th Percentile
Max. Weight 25th Percentile
Max. Weight 10th Percentile
Company Name
Job Name
Last Name
First Name
Middle Name
Gender
Lateral Position
Sagittal Position
Twisting Position
Lateral Velocity
Sagittal Velocity
Twisting Velocity

Average Lateral Velocity


Maximum Lateral Velocity
Average Sagittal Velocity
Maximum Sagittal Velocity
Average Twist Velocity
Maximum Twist Velocity
Maximum Lateral Acceleration
Maximum Sagittal Acceleration
Maximum Twisting Acceleration
Action Limit Origin
Action Limit Destination
MPL Origin
MPL Destination
RWL Origin
RWL Destination
Lifting Index Origin
Lifting Index At Destination
Initial Force
Initial Force 90th Percentile
Initial Force 75th Percentile
Initial Force 50th Percentile
Initial Force 25th Percentile
Initial Force 10th Percentile
Sustained Force
Sustained Force 90th Percentile
Sustained Force 75th Percentile
Sustained Force 50th Percentile
Sustained Force 25th Percentile
Sustained Force 10th Percentile
Run Date
Run Number
Task Name
Trial Number
Time (frequency of 60 Hz)
Lateral Acceleration
Sagittal Acceleration
Twisting Acceleration

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Project Menu
Collect Data

View Data

Analyze
Data

New
Company
New Job
New
Employee
New Task

This option initiates a profile selection for iLMM data collection. The user will be
prompted to select a COMPANY, JOB, and EMPLOYEE for which the subsequent data
are to be collected. If needed, the NEW button beside each identifier can be selected,
for the user to name a previously undefined company/job/employee.
The fourth profile option, LMM SIZE, is for adjusting the iLMM offsets. This is
needed for the BIOMEC iLMM only. The selection of this profile factor must match
that to which the iLMM is positioned. At this point, the paired iLMM size to be worn
by the employee should remain on its zero-plate for offset adjustment prior to data
collection.
Following iLMM data collection, this option allows the user to view the lateral, sagittal,
and twist trunk motion profiles for each trial. Up to five trials can be viewed at one
time, which can be selected: BY JOB; BY TASK; BY JOB/EMPLOYEE; and BY
EMPLOYEE/TASK.
After iLMM data have been collected and viewed, this option allows the user to perform
risk analyses using the LBD risk model. After the workplace data needed to calculate
LBD Risk have been entered (i.e., Load Weight, Frequency, Moment Arm), the analysis
can be performed from the four following options. Note that a minimum of three trials
of a particular task should be selected to run the LBD Risk analysis. This was based on
previously published research (WG Allread, WS Marras, and DL Burr, Measuring trunk
motions in industry: variability due to task factors, individual differences, and the
amount of data collected, Ergonomics, 43(6):691-701, 2000).
LBD risk calculated from data collected across all tasks and
Overall
employees who performed the selected job in a particular company.
Job Risk
LBD risk calculated from data collected for all employees who
Overall
performed a chosen job task within a company.
Task Risk
LBD risk calculated from data collected for all tasks within the
Job Risk
selected
company, job, and employee.
by Employee
LBD risk calculated from data collected on a particular job task,
Job Risk
specific
to the employee selected from the chosen company.
by Task
This option allows the user to name and describe a previously unidentified company to
the current PROJECT file. This can also be done using the COMPANY hot button.
This option creates a newly defined job within the COMPANY chosen. The JOB hot
button can also be used.
This option allows the user to identify an additional employee who will be monitored
within the selected COMPANY. The EMPLOYEE hot button can also be used to
perform this action.
This option adds a new task to be monitored within the chosen JOB and COMPANY.
The action can also be done using the TASK hot button.

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Database Hierarchical Structure
The left side of the BALLET 2.4 main screen contains the hierarchical structure of the database (Figures
13 and 14). Within a Project, the main categories consist of Company, Jobs, Tasks, Runs, and
Employees.

Company
Job
Tasks
Material handling
components of
the job necessary
to complete job
functions.

Runs
Data collection
sessions, each
consisting of
multiple trials
from one or more
tasks performed
by a particular
Employee.
Employee
The individual performing
the job and tasks during data
collection. The date of the
Run of Trials and Run
Number are also listed.

Trial
One observation of a Task performed by an Emp loyee. A trial is
linked with the name of the Task that was performed. It contains
trunk motion d ata from the iLMM, workplace measurements, and
object characteristics. The Trial Number is shown to the right of
the trial name within the collected Run.

Figure 13. BALLET 2.4 main screen.

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Tab for inputting basic


Emplo yee information

Tab for inputting Employee


anthropometric measurements

List of Employees with iLMM data within a sp ecific Company

Figure 14. Employee level of the hierarchical structure.

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Data Editing of Trials and Analysis Set Up
Data editing of the trials can be accomplished by highlighting the trial in the hierarchical tree of the
main screen, then right-clicking on the trial. A menu box will appear with the following options:
Delete

Permanently deletes a trial from the database. This may be necessary so that invalid data
are not included in LBD Risk Analyses as well as other functions of the BALLET 2.4
software. For example:
The employee performed an unexpected task that doesnt correspond to the intended task
being collected;
Unrealistic trunk motion profiles occurred for the task; or
The employee started the task, but didnt finish it, and the user collected the trial anyway.

Rename

Allows for a new Task name to represent the trial. This situation may arise if the wrong
Function key was used to collect trial data, causing the data to get stored under another Task
name instead of the one intended. When this option is used, a selection box will appear,
allowing the user to select the correct Task name from those previously entered.

NIOSH
1981

Allows the user to enter and accept the trial data as inputs into the 1981 NIOSH Work
Practices Guide for Manual Lifting. The trial level input data must be generated and
accepted by clicking the OK button (Figure 15), before the 1981 NIOSH Action Limit
(AL) and Maximum Permissible Limit (MPL) can be calculated and viewed on the NIOSH
folder for trial data (Figure 16) or exported into a file. A one-page report can be generated
by clicking on the Report button (top-right of Figure 15). Reports can be printed by
clicking on the Tool Bar printer icon. The report includes input data for the lifts origin and
destination and the resulting AL and MPL.

NIOSH
1991

Allows the user to enter and accept the trial data as inputs into the 1991 Revised NIOSH
Lifting Equation. The trial level input data must be generated and accepted by clicking on
the OK button (Figure 17), before the 1991 NIOSH Recommended Weight Limit (RWL)
and Lifting Index (LI) can be calculated and viewed on the NIOSH folder for trial data
(Figure 15) or exported into a file. A one-page report can be generated by clicking on the
Report button (top-right of Figure 17) and printed by clicking on the Tool Bars printer
icon. The report includes input data for the origin and destination, and the resulting RWL
and LI.

Psychophysical

Allows the user to enter and accept the trial data as inputs into the Psychophysical analysis.
The data entry screen is shown in Figure 18, and the Psychophysical tab for the trial data is
shown in Figure 19. A one-page report can be generated by clicking on the Report button
(top-right of Figure 18) and printed by clicking on the printer icon on the Tool Bar. The
report includes input data for the material handling activity and the resulting maximum
acceptable weight or force for that activity, by gender and percentile.

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Figure 15. 1981 NIOSH Work Practices Guide for Manual Lifting data input screen from trial data
of the BALLET 2.4 database.

Figure 15. BALLET 2.4 NIOSH 1981 and 1991 folder calculations from the trial data.

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Figure 17. 1991 Revised NIOSH Lifting Equation data input screen from trial data of the Ballet 2.4
BALLET 2.4 database.

Figure 18. Psychophysical analysis data input screen from trial data of the BALLET 2.4 database.
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Figure 19. BALLET 2.4 psychophysical folder calculations from the trial data.

Setting up the Hierarchical Structure


Project, Company, Job, Task, and Employee data can be entered into the software using input screens.
Project. The project file (*.mdb) contains the database of the hierarchical structure for data collection
and retrieval, as well as the collected data. The project file is structured using a Microsoft Access
format. To define a PROJECT, select New Project from the FILE menu, or click on the New
Project icon on the Tool Bar. A New Project file-naming screen will next appear. Type the name of
the new PROJECT.
Company. When defining a new COMPANY, use the mouse and click on the COMPANY hot button,
or select NEW COMPANY from the PROJECT menu. A data input screen will appear for Company
and Contact information to be input (Figure 20). When the desired information is entered, select OK
at the bottom of the data entry form to exit this screen.

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Name
The name of the company
for which iLMM and
workplace data are being
collected. (Required)

Description
A short description of the
company. (Optional)

Primary SIC
Primary Standard
Industrial Classification
(SIC) code for the
company. (Optional)

Figure 20. Company information data entry screen.


Job. Using the mouse, click on the JOB hot button, or select NEW JOB from the menu. A pull-down
menu will appear that prompts the user to select the appropriate company that the job corresponds to.
Select the correct COMPANY then select OK at the bottom of the form. A JOB data entry form will
appear (Figure 21), prompting input of Job Name, Description, Department, and LBD Risk Model Lift
Rate information.
Task. Click on the TASK hot button, or select NEW TASK from the PROJECT menu. A pull-down
menu box will appear that prompts the user to select the appropriate company and job corresponding to
this task. Click OK after entering the correct information. A NEW TASK data entry form will
appear, prompting input of data into two different folders; the Task and Psychophysical folders. Refer
to Figures 22 through 25 for inputting data in these forms and to Chapter 5 for descriptions on how to
make the measurements correctly.
Note: No more than eight individual MMH tasks can be defined for each job.
Note: Any data entered manually at this stage will apply to all subsequent trials collected for this task.
For example, if an objects vertical start and end heights for a lifting task do not change from trial to
trial, then entering these measurements before data collection will link them to all subsequent trials,
eliminating the need to enter them manually after each trial collected. However, if the heights change
from trial to trial, then they will need to be entered for each trial following data gathering.

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Job Name
The name of the job.
(Required)
Description
A short description of the job
or job function. (Optional)

Department
The name of the department
where the job is done.
(Optional)

LBD Risk Model Lift Rate


The lifting frequency (per
hour) across all materials
handling job tasks used in the
analysis (Required).
This information is required
to run the LBD Risk model.
See Chapter 4 for instructions
on how to calculate Lift Rate.

Figure 21. Job information data entry screen.

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Vertical Start Height; Vertical End Height
Task Name
The origin and destination heights for the object The identifier given to a jobs
used in the MMH activity (e.g. lift, lower, push, MMH subtask. (Required)
pull), measured vertically from the floor to the
midpoint of the hands. (Required for the 1981
Description
and 1991 NIOSH lifting equations and the
An explanation of
psychophysical analysis)
the task. (Op tional)

Moment Arm a t Origin; Destination


The horizontal distance fro m the L5 /S1
intervertebral disc and the midpoint
between the hands, measured at the
beginning and end of the MMH
activity. (Required for the LBD Risk
model analysis)

Coupling
A pull-do wn
menu to select
the quality of
the
employees
grip on the
load being
handled .
Options are
Poor, Fair, or
Good.
(Required for
the 1991
NIOSH lifting
equation)

Load Weight
Weight of the
object lifted or
lowered during the
MMH activity.
(Required for the
LBD Risk model
and the 1981 &
19 91 NIOSH
lifting equations)

Lifting Frequency
The lifting rate for this
specific task. This variable is
not the Lift Rate used in the
LBD Risk model, which
covers the frequency across
all job tasks. (Required for
the 1981 and 1991 NIOSH
lifting equations)

Activity
A pull-down menu that
allows selection of the
type of material handling
activity that the task requires.
Options are Lift, Lower,
Push, Pull, and Carry.
(Required to perform the
psycho physical analysis)

Duration
The length of time the
employee is engaged in
the MMH activity (e.g.,
eight hours). (Required
for the 1981 and 1991
NIOSH lifting
equation)

Asymmetry at Origin and


Destination
The angle formed by the
plane across the employees
shoulders compared to that
across the hips, at the origin
and destination of the MMH
activity. (Required for the
1991 NIOSH lifting equation)

Initial and Sustained Forces


The push or pull force required to begin and continue movemen t
of an object. (Required the push/pull psychophysical analysis)

Figure 22. Task information data entry screen.

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Activity
A pull-down menu for selecting the
type MMH activity performed.
Options include :Lift, Lower, Push,
Pull, and Carry.

Gender
A pull-down menu
for selecting the
employees gender.

Object Depth
A pull-down menu for selecting the
depth of the object being handled (in
the sagittal plane). Choose the depth
closest to the actual value measured.

Location
A pull-down menu for
selecting the objects
vertical position during
the activity, referenced to
the employees body.
Lifting task options are:
Floor to Knuckle
Knuckle to Shoulder
Shoulder to Reach
Lowering task options:
Knuckle to Floor
Shoulder to Knuckle
Reach to Shoulder

Frequency
A pull-down menu for
selecting the rate at
which the MMH
activity occurs. Choose
the frequency closest to
the actual value
computed.

Maximum Acceptable Weight (of Lift or Lower)


Display of the psychophysical analysis results, based
upon the task parameters input. Values range from
10th to 90th percentile of acceptance, for both males
and females.

Vertical Travel Distance


A pull-down menu for selecting the height
range than the object is lifted/lowered.
Choose the distance closest to the actual
value measured.

Figure 23. Task psychophysical data entry screen for lifting and lowering activities.

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Activity
A pull-down menu
for selecting the
type MMH
activity performed
(Push or Pull).

Gender
A pull-down menu
for selecting the
employees
gender.

Distance
A pull-down menu
for selecting the
length an object is
pushed or pulled.
Choose the
distance closest to
the actual value
measured.

Height
A pull-down menu
for choosing the
vertical location of
the hands when the
object is being
pushed or pulled.
Choose the height
clo sest to the
actual value
measured.

Frequency
A pull-down menu
for selecting the
rate at which the
object must be
pushed or pulled.
Choose the
frequency closest
to the actual value
comp uted.
Maximum Acceptable Force of Push/Pull
Display of the psychophysical analysis results, based upon the task parameters input. Two estimates of maximum
acceptable push or pull force are shown. The Initial Force is the maximum acceptable level of pushing/pulling to begin
movement of the object. The Sustained Force is the maximum acceptable amount of pushing/pulling necessary to maintain movement of the object. Acceptance values range from the 10th to the 90th percentile, for both males and females.

Figure 24. Task psychophysical data entry screen for pushing and pulling activities.

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Distance
A pull-down menu
for selecting the
distance an object is
carried. Choose the
distance closest to
the actual value
measured.
Frequency
A pull-down menu
for selecting the rate
at which the object
must be carried.
Choose the
frequency closest to
the actual value
computed .

Gender
A pull-down menu
for selecting the
employees gender.

Height
A pull-down menu
for choosing the
vertical location of
the hands when the
object is being
carried . Choose the
height closest to the
actual value
measured.

Maximum Accepta ble Weight of Carry


Display of the psycho physical analysis results, based upon the task parameters input. Values range from 10th to
90th percentile of acceptance, for both males and females.

Figure 25. Task psychophysical data entry screen for carrying activities.

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Employee
Using the mouse, click on the EMPLOYEE hot button, or select NEW EMPLOYEE from the PROJECT
menu. A pull-down menu box will appear that prompts the user to select the company for whom the
EMPLOYEE works. Click on OK when the correct information is entered. A NEW EMPLOYEE
data entry form will then appear, prompting input of data into two different tabs. The Employee tab is
for name, birth date, and gender information (see Figure 26), while the Measurements tab allows for
several commonly used anthropometric measurements to be input (see Figure 27).

Figure 26. Employee information data entry screen.

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Weight Shoulder Height Stature
Standing
Employee Height of the
height.
weight.
acromion.

Elbow Height
Height from the floor to the bottom
of the elbow when flexed at 90 deg

Left Iliac Height


Vertical height,
measured from the
floor to the left
iliac crest.

Right Iliac Height


Vertical height,
measured from the
floor to the left
iliac crest.

Upper Leg Length


Distance measured
from the greater
trochanter to the
top of the patella.

Lower Leg
Length
Distance measured
from the top of the
patella to the floor.

Upper Arm
Length
Distance from the
acromion process
to elbow, with the
elbow at a 90 deg
angle.

Lower Arm
Length
Distance from the
elbow to the tip of
the 3r d digit, with
the elbow at a 90
deg angle and
fingers extended,

Trunk Length
Length of the
trunk, measured
from C1 to S1.
Iliac Breadth
Trunk breadth
measured at the
level of the iliac
crest.

Trunk
Circumference
Distance around
the trunk, measured
at the level of the
iliac crest.
Xiphoid Breadth
Trunk breadth measured at
the level of the xiphoid
process.

Xiphoid Depth
Trunk depth measured at
the level of the xiphoid
process.

Iliac Depth
Trunk depth measured
at the level of the iliac
crest.

Figure 27. Employee measurement data entry screen.

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Collecting Data
To collect data, first make sure that the iLMM
system is configured properly and powered on.
Next, click on the COLLECT hot button, or
select COLLECT DATA from the PROJECT
menu. A pull-down menu box will appear
(Figure 28), which allows for selections of
Company, Job, Employee and iLMM Size to be
used for the data collection session. Click on
OK when the correct information is entered.
Note: The LMM Size needs only to be selected
when working with the BIOMEC LMM system.
When using the LMM3 system, the correct LMM
Size (LMM3) will be automatically selected.
Figure 28. Job/Employee profile data
Note: The system provides two confirmations
collection screen.
that iLMM signals are being transmitted. (1) The
light on the USB radio rapidly blinks GREEN.
(2) The software displays (Status: comX -> Data Streaming) to the right of the Menu options.
Note: It is important that the sound for the notebook computer being used for data collection is
turned on, as the system will alert the user (beeping) there is interference with the iLMM signal.
Adjusting iLMM Offsets
For the BIOMEC LMM System: Any time a different/new Employee or iLMM Size is selected for data
collection, the software will require the user to adjust the iLMM offsets, which eliminates the potential
for any incorrect data to be gathered. With the iLMM still in its box (or removed from the waist belt and
back in the case) and turned on, click on the COLLECT hot button, select a Company, Job, Employee
and iLMM Size, and the Calibrate iLMM screen will appear (Figure 29).
Traces from the iLMM will appear and begin to scroll across the screen. Select the correct iLMM size
and then click on the ADJUST button to zero the iLMM Offsets. After these offsets have been adjusted,
the traces should follow the zero angle horizontal line across the screen (Figure 29). Click okay to
complete this step and begin data collection.
For the LMM3 System: No iLMM offset adjustment is needed. If used with this iLMM, always
perform the operation with the unit in its storage plate. This screen can be useful, however, to ensure
that the iLMM is fit correctly on the employee. That is, with the employee standing upright, the lateral
position (red trace) and twisting position (yellow trace) should be at or near zero deg. The sagittal
position (green trace) should reflect a negative angle, but this angle will vary depending on the
employees amount of lordosis (i.e., inward curvature of the lumbar spine). Those with slight lordosis
(less curvature) will have smaller negative angles, while those with more lordosis (greater curvature)
will have larger negative angles.
Note: When using either the BIOMEC or LMM3 systems, never adjust offsets when the unit is
being worn by the employee. This will result in incorrect data being collected.

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Figure 29. The iLMM offset adjustment screen.

After the iLMM Offsets have been adjusted, a data collection screen will appear (Figure 30). The
iLMM is now ready to be attached to the waist belt and, with the shoulder harness, placed on the
employee.
Collecting Data
The data collection screen (Figure 30) is used to observe iLMM motion traces and mark when the
employee is performing the MMH tasks of interest. The top of this screen shows instantaneous threedimensional trunk motions. The lower left box of the screen serves as a check that the correct Company,
Employee, Job, and LMM Size have been selected. It also shows a running tally of the individual data
collection sessions (defined as Runs). The lower right box on the screen contains a list of those job tasks
that were previously defined. Each Task is linked to a keyboard Function key (F1 through F8).
To begin an iLMM data collection session (defined as a Run), press the Start button on the Data
Collection screen. This button will disappear and be replaced by a Stop button when data collection is
occurring. Use of the corresponding Function keys will allow for iLMM data collection to occur.

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Run
The number of the
current data collection session, which
increments each time
a new session begins.

Box showing the name


of the Co mpany,
Employee, Job, and
LMM Size chosen for
this current data
collection session.

# Trials
An incremental
tally of the trial
co llected for a
particular task.

Box showing a list of all tasks defined


for a particular job. Tasks correspond
to separate Function keys, which are
used to collect iLMM trunk motio n
data. Up to eight tasks can b e defined.
Long Task names will be truncated.

Figure 30. Data collection screen.


To begin task data collection (e.g., when the employee starts to lift the object of interest), press the
appropriate Function key once. A green vertical line will appear on the screen with the corresponding
Function key label, which indicates that the data collection for a trial has begun.
To note the end of iLMM MMH task (e.g., when the object has been set down), press the appropriate
Function key again. A red vertical line will appear on the screen, along with the corresponding Function
key label, indicating the data collection for the trial was stopped. The number of trials collected for a
task is indicated next to the Function key and Task name on the lower right of the Data Collection
screen.
To stop and save data collected within a Run, press the Stop button and then the Save Run button. It is
recommended that a Run of trial data be saved frequently, since the maximum Run time for a data
collection session is about five minutes.

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If a Function key is used for a MMH task that was not previously defined, the software will require the
user to name this task before further data collection can begin.
To begin a new Run, press the Start button again. Note that the Run number has changed. These Run
and Trial numbers marked for the various MMH trials are very useful during later data processing, as
they are a way to edit or delete any information that was gathered.

Viewing Data
Following data collection, the trunk motions gathered can be reviewed. Summary statistics of the data
of interest for each trial can also be accessed. Trunk motion profiles should be viewed to ensure that
reasonable and valid data were collected and are being used to reach any conclusions. It is especially
important to review all data prior to performing an LBD Risk analysis (to be discussed in another
section of the Manual). This will help to identify unexpected motions (e.g., data are gathered as the
employee does additional MMH besides that of interest) or unreasonable data (e.g., interference with the
iLMM signal generates trunk motions that are biomechanically implausible) that should be removed
from any analyses.
To view data, click on the VIEW hot button, or select VIEW DATA from the PROJECT menu list. A
selection screen will appear with a list of trials, and trial information (employee, run date, run number,
trial name and trial number). The trials can be categorized in four different ways:

By Job, which will list all the trials associated with all employees who performed the job of
interest (Figure 31);
By Task, which will list all the trials associated with all employees who performed the task of
interest (Figure 32);
By Job/Employee, which will list all the trials associated with the selected employee performing
the job of interest (Figure 33); and
By Employee/Task, which will list all the trials associated with a particular employee and specific
task (Figure 34).

Figure 31. Viewing data using the By Job trial selection screen.
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Figure 32. Viewing data using the By Task trial selection screen.

Figure 33. Viewing data using the By Job/Employee trial selection screen.

Figure 34. Viewing data using the By Employee/Task selection a screen.


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Use the mouse to select the trial(s) to view. Sequential trials can be selected by keeping the mouse
button pressed and dragging it across the trials of interest. Non-sequential data can be selected by
holding down the Shift key and using the mouse to click on the desired trials.
Note: Data from a maximum of five trials can be selected and viewed at any one time.
After clicking OK, a Trial Data screen (Figure 35) will appear that shows the trunk kinematics (i.e.,
position, velocity, and acceleration) for the chosen trials. Each is represented by a different color trace.
In addition, trunk motion summary data are shown in a table at the bottom of this screen, which are
color-coordinated with the motion traces. The Run Date, Run #, and Trial # for the selected trials are
displayed in this table, as are three trunk kinematic variables. These three variables (i.e., Average
Twisting Velocity, Maximum Sagittal Flexion, and Maximum Lateral Velocity) are the specific
measures used in LBD Risk analyses. However, all trunk kinematic summary data for a chosen trial can
be viewed by double-clicking the corresponding row. An example is these trial statistics is displayed in
Figure 36.

Analyzing Data
This option for selected trials to be analyzed using the LBD Risk model. It is recommended that the
collected trunk motion profiles be thoroughly investigated, through the VIEW DATA option, before an
LBD Risk analysis is performed. This will help to ensure that valid data are being used in the analysis.
It is recommended that a minimum of three (3) trials be included when reporting results using the LBD
Risk model.
To analyze data, click on the ANALYZE hot button, or select ANALYZE DATA from the PROJECT
menu. From this, a Select Risk Model screen will appear, from which LBD Risk analyses can be
selected in one of four groupings:

Overall Job Risk, which will use data from the trials associated with all employees who performed
the job selected (Figure 37);
Overall Task Risk, which will use data from the trials associated with all employees who
performed the task of interest (Figure 38);
Job Risk by Employee, which will use data from the trials associated with a particular employee
performing the job selected (Figure 39); and
Job Risk by Employee/Task, which will use data from the trials associated with a particular
employee and task (Figure 40).

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Selection boxes for each motion plane, which allows that data to be shown or hidden.

Trunk position
traces for the
chosen trial(s)

Trunk velocity
traces for the
chosen trial(s)

Trunk acceleration
traces for the cho sen
trial(s)

Selection boxes for


each selected trial,
which allows that
data to be shown or
hidden.
Additional trial statistics that can be viewed are
minimum and maximum positions, peak and average
velocities, and peak and average acceleration in each
of the three planes of motion..

Summary statistics for the


selected trials (up to five
can be viewed at any one
time).

Figure 35. Viewing trunk kinematic data for one trial.

Figure 36. Trunk motion summary statistics for a trial.

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Figure 37. LBD Risk model analysis trial selection screen for Overall Job Risk groupings.

Figure 38. LBD Risk Model analysis trial selection screen for Overall Task Risk groupings.

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Figure 39. LBD Risk model analysis trial selection screen for Job Risk by Employee groupings.

Figure 40. LBD Risk model analysis trial selection screen for Job Risk by Employee/Task
groupings

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After the desired Risk Model grouping has been selected, all trials, by default, will be highlighted in the
selection box and be included in the LBD Risk analysis. Trials can be excluded from the analysis by a
mouse click; this will deselect (un-highlight) data the user wishes to not include in the analysis.
When the desired trials have been selected for the LBD Risk analysis, click the OK button. This will
generate an LBD Risk model analysis, and the corresponding bar chart will appear (Figure 41). See
Chapter 5 for the appropriate interpretation of LBD Risk model outputs (i.e., the resulting Probability
of High Risk Group Membership).
If there are missing data needed for an LBD Risk analysis to be performed (e.g., lift rate, load weight,
moment arms), the software will guide the user to these data fields so that the necessary data can be
input.
LBD Risk value computed for
the trials selected for analysis

Magnitude of each of the five variables


included in the LBD Risk analysis (percentage)

Workplace and trunk kinematic variables used


in the LBD Risk model analysis

Print button for sending


chart to printer

Figure 41. LBD Risk model analysis bar chart.

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Chapter 4 Using the ACUPATH iLMM


and LBD Risk Model
Selecting the Job(s) to Monitor
The iLMM can be used to monitor the instantaneous positions, velocities, and accelerations of the trunk
in the three cardinal planes of motion for practically any job in which trunk movements are required.
This type of information is important for describing the movement requirements of a job or other
activity. The LBD Risk model is composed of five workplace and trunk motion factors that, when
combined, assesses the probability that a job will have high numbers of LBDs associated with it. This
model is also useful for establishing relative comparisons between jobs or several tasks that comprise a
single job.
The industrial jobs used to develop the LBD Risk model had MMH frequencies ranging from about six
to nearly 1,500 separate lifting tasks required per hour. Thus, the tasks to be assessed using this risk
model should fall within this scope of lifting rates. Most MMH jobs fit this profile. For example, in
automobile assembly, job cycles are repeated every one to two minutes, and the parts themselves often
are standard in size and weight. Palletizing jobs may require very different types of objects to be
handled, but the task of continual lifting from one storage unit to another remains the same. These types
of jobs are very consistent with those previously used to develop the risk model database, and the jobs
LBD Risk can be easily assessed with the iLMMs BALLET 2.4 software.
Some jobs are less repetitive or have more job variation than traditional assembly or palletizing tasks.
However, the LBD Risk model still can be used to make relative comparisons between the tasks that
comprise the job. For jobs that require a larger number of tasks, the risk model is helpful in comparing
the factors that make up the model. This will allow the investigator to assess trade-offs between such
factors as lifting frequency, object weights handled, and the trunk motions required for the different
tasks. It should be noted that there is inherent variability in the way different employees perform the
same task or a single employee performs one task repeatedly. Research has indicated that if three
employees are monitored for the same job and tasks, and the task variables do not differ from trial to
trial (e.g., start and finish heights), then a minimum of three observations of the task are necessary to
describe the job (WG Allread, WS Marras, and DL Burr, Measuring trunk motions in industry:
variability due to task factors, individual differences, and the amount of data collected, Ergonomics,
43(6):691-701, 2000). However, if there are fewer than three employees to monitor for a given
job/task, or the task parameters vary from trial to trial, then it is recommended that more than three
trials be collected for a give task.
Another workplace factor to consider is job rotation. Employers often use a variety of rotation schemes
for job processes. If the job to be monitored requires no rotation (employees perform the same job every
day/week/month), then the LBD Risk assessment can be directly related to the tasks observed. Jobs in
which employees rotate regularly between two or more work areas also may be used in assessing LBD
risk, if this rotation schedule is fixed. When the job rotation requires employees to perform completely
different jobs on an hourly or weekly basis, it becomes difficult to relate a tasks risk value to the overall
job risk, since many tasks could contribute to the risk assessment. This is a key factor in determining a

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jobs suitability for LBD Risk assessment. That is, does the jobs work structure enable one to define
the job in terms of a limited number of repeatable, consistently performed tasks?
There may be some jobs that fit within the LBD risk model profile but still should not be monitored.
Seated jobs may require repetitive activities, but they usually are not ones that require significant MMH.
In any event, the iLMM may contact the seats back or the waist belt may shift from its position on the
hips during seated work, and erroneous output will result. Also, jobs that require close contact of the
iLMM with a finished product could produce scratches on the product, and the employer may not want
to risk product damage. Finally, exposure to water or other liquids may damage iLMM electronics.

Defining the Major Job Components through a Task Analysis


It is very important to properly define all relevant tasks that comprise the job of interest. These tasks
should encompass the range of MMH work that is required of the job, especially those that may create
risk for an employee to develop a LBD. The tasks also should be defined so they are meaningful to
those who will be interested in the iLMM results. One way to define these job tasks is through a task
analysis. In this case, a task analysis defines the discrete MMH events of a job.
As an example, consider a job that may be performed in a food processing plant (shown in Figure 42).
An employee places twelve frozen food packages (two at a time), into a box (a), records the date and
time of the packaging (b), and then loads the packed box onto a pallet (c). A simple task analysis of this
job is shown in Table 1. Two of the three tasks identified would qualify as material handling tasks for
this job loading the individual packages and placing the full box onto the pallet. Recording the date
and time of the packaging would not be considered relevant MMH since low forces and exertions are
required. Any trunk movement related to this task would not be considered in further analyses. However, trunk kinematics and LBD Risk could be determined for the two relevant MMH tasks identified.

a.

b.

c.

Figure 42. The three tasks of the frozen food packager job: (a) place two packages in box; (b)
record date/time of packaging; and (c) load full box onto pallet.

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Task

Task Length

Place two food packages in box

42 seconds

Record date/time of packaging


Load full box onto pallet
Total time of job tasks

10 seconds
8 seconds
60 seconds

Notes
Task time is seven seconds per two boxes
packaged; twelve packages fit into each box.
No material handling is required.
A full pallet contains seven layers of boxes.

Table 1. Task analysis of one cycle of the frozen food packager job.
It may be convenient to sub-divide and redefine a task that is similar in all but one or two workplace
requirements. For instance, in the above example, a fully loaded pallet contains boxes stacked seven
layers high. Tasks could be defined separately as "Place box on Layer 1," "Place box on Layer 2," etc.
This may assist data interpretation. That is, differences in trunk kinematics could be interpreted not only
as a function of the defined job tasks, but also in terms of specific workplace factors, such as a load's
location.

Collecting and Recording Workplace Data for Risk Assessment


The trunk kinematic data used in the LBD risk model is automatically stored in BALLET 2.4 software.
Trunk motions include the positions, velocities, and acceleration of the trunk in its three planes of
motion the lateral (side-bending) plane, the sagittal (forward-bending) plane, and the rotational
(twisting) plane. Two other components, Lift Rate and Maximum Moment, must be determined and
input manually.
Lift Rate. Lift Rate is defined as the total number of MMH actions that a job requires per hour. This
number is related to the total lifts across all tasks being monitored; it does not change from one task to
another in the job. As the task analysis in Table 1 found, on average, one box is fully prepared and
loaded onto the pallet per minute. Assuming this rate represents an average job cycle across the work
shift, the packaging task alone would require 360 lifts per hour, since the product is placed in each of the
60 boxes six times (two packages per lift). For the palletizing task itself, 60 lifts are required per hour,
for each fully packed box. Both tasks combine for a total of 420 lifts required per hour for this job. The
non-MMH date/time-recording task would not influence the lifting frequency of the job.
Because the Lift Rate value is directly input into the LBD Risk model, it is very important to accurately
calculate the jobs lifting frequency. The task analysis results can be confirmed by questioning
employees familiar with the job, speaking with the job supervisor, or looking a production records.
Maximum Moment. Maximum Moment is defined as the external horizontal moment generated about
the spine. A moment is composed of two factors the weight of the object being handled and the
horizontal distance from the spine at which it is handled.
Weight. Each object handled on a job must be weighed and recorded in the software or noted manually
and input during data analysis. If objects of varying weights are handled, then each must be weighed
individually and recorded. This often occurs, for example, in mail and freight delivery operations. In
the aforementioned food-processing example, the weights are constant for each task. The combined
weight of the two food packages lifted together needs to be recorded, as should the weight of a fully
packed box being palletized.

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Horizontal Distance. A tape measure is
needed to determine how far from the spine
objects are being handled for each task. With
the tape measure held horizontally, one must
measure the distance from the spine at the
lumbosacral joint (near the top of the hips) to
the center of the hands when the task is being
performed. Obviously, as employees handle
objects, this distance can change as the object
is moved. It is important to determine at what
point during the task the distance is the
greatest (i.e., generating the greatest moment
about the spine) and to record this length. A
correctly measured horizontal distance is
shown in Figure 43(a). Here, the tape
Figure 43. Correct (a.) and incorrect (b.) methods
measure is kept level to determine the length
of measuring the distance a load is held
from the employees L5/S1 joint to the center
from the L5/S1 joint.
of the hands. The incorrect approach is being
used in Figure 43(b), since the distance being measured is not horizontal.
For some MMH jobs, perhaps those on an assembly line, work requirements can be very repetitive and
the employees' actions and movements rather consistent. In these cases, the horizontal distances may
not vary much, as identical objects are handled on each cycle. For other jobs, such as when pallets are
loaded or unloaded, each cycle can produce very different trunk motions, since objects are being
handled from different areas. This will likely change the horizontal distance at which an employee
handles each load. Because the Maximum Moment value (a multiple of an object's weight and its
horizontal distance held from the spine) is directly input into the LBD Risk model, it is important to
accurately measure these distances for each task cycle being monitored using the iLMM.
Note: Measurement of these horizontal distances should not interfere with the work being done by the
employee. The investigator who measures these distances should stand close enough to the employee to
get accurate readings, but far enough away to not disturb the work. It is important that the employee be
able to move naturally at the job site. A monitored employee being crowded by an investigator will
move differently, change his/her trunk motions, and give erroneous information via the iLMM.

Collecting the Data


After the job to be monitored has been selected, its MMH tasks identified, and basic workplace
information gathered, the data collection process can start. To begin, the iLMM, waist belt, and
shoulder harness need to be prepared for use and correctly placed on the employee. See Chapter 2 for
step-by-step instructions.
After the iLMM is properly placed on an employee and found to be transmitting a signal, the
investigator is ready to gather trunk motion data. It is suggested that the employee monitored be given
some time (a few job cycles, for example) to become accustomed to the iLMM before collecting data.
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The main goal of data collection is to gather information on trunk motions that are representative of all
the work required of the job. For example, if the job requires handling objects of widely varying
weights or from different locations (on a pallet, for example), then data should be gathered from each of
these tasks. The more data that are collected will likely better represent the jobs trunk motion requirements. The amount of data collected also should be reflective of the job and how it is structured. For
example, if 80% of the job requires doing Task A and only 20% doing Task B, then a majority of the
data should be of the employee performing Task A. In other words, data collection should be
proportional to the job being studied.
There is no set number of job cycles that indicates when enough data have been collected. It is
dependent on the nature of the tasks. Jobs that are highly consistent in their activities usually require
fewer numbers of collected cycles than those with more widely varying work requirements. Research
has indicated that if three employees are monitored for the same job and tasks, and the task activities do
not differ from trial to trial (e.g., start and finish heights), then a minimum of three observations of the
task are necessary to describe the job (Allread et al. 2000). However, if there are fewer than three
employees to monitor for a given job/task, or the task parameters vary from trial to trial, then it is
recommended that more than three trials be collected for a given task.
Note: It is extremely important to keep a record of the weights handled and the measured horizontal
lifting distances for each task cycle collected, so that these data are matched with the corresponding
trunk motion data for that cycle. An example form is shown in Table 2. The investigator may wish to
develop a customized data collection form beforehand to keep track of this information.

Company: ___________________________________________________________________
Job: ________________________________________________________________________
Employee: ___________________________________________________________________
Date: _______________________________________________________________________
Trial #

Task

Object
Weight

Horizontal
Distance

Start
Height

Finish
Height

Comments

Table 2. Example data collection form.


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Chapter 5 Analyzing and Interpreting the Data


By following the guidelines in the previous chapters, data analysis and interpretation will be made
easier. Tasks of a job that are carefully chosen will assist in interpretation of LBD Risk for a job and
lead to results having more practical significance. The BALLET 2.4 software used to collect and
analyze iLMM data has the ability to provide trunk kinematic information and LBD Risk charts for each
task defined within a job, across all job tasks, for each employee who was monitored, and (averaged)
across all employees performing the same tasks or job.
Trunk Kinematic Information. Information about specific trunk motions produced by employees
during the MMH tasks can be obtained from the BALLET 2.4 software. This includes the trunk
positions, velocities, and accelerations generated by the trunk for each plane of motion for those task
cycles chosen by the investigator. This information can be useful for general descriptions of the MMH
or for comparisons with other tasks or jobs. Use of these data can be valuable for investigators who
have formed hypotheses about, for example, what tasks require more trunk motions than others.
LBD Risk (Probability of High Risk Group Membership) The BALLET 2.4 software will produce
information that compares the jobs and tasks of interest with a database of MMH jobs previously
determined to have "high" or "low" rates of employee LBDs associated with them. The interpretation of
data is best described through continued use of the food packager example.
In the food-packaging job, two tasks were defined. The first task involved placing individual frozen
food packages into a box (twelve in all), and the second task involved loading the filled box of packages
onto a pallet. LBD Risk charts are shown for each task, in Figures 44 and 45. In Figure 44, the
package-loading task was
found to have a risk
probability of 40%.
(Probability values are
calculated by averaging the
individual logits, or
component risk factor
distributions, from each of
the five risk factors used in
the model. In this case,
Figure 44 shows this to be
40% (i.e., the average of
99%, 30%, 3%, 23%, and
45%). Using the same
method, the probability
value for the palletizing
task (Figure 45) was
calculated to be 64%.
Clearly, the palletizing task
Figure 44. LBD Risk chart for the frozen food packager job, for the
is more similar to those
Place Two Food Packages in Box task.
previously considered

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high risk Than package
loading. These two
probability values are to be
used only for comparison
purposes. It is the
summary chart (Figure 46)
that reflects the true LBD
Risk for the entire job.
This chart summarizes the
largest values for each risk
factor across both tasks that
comprise this job. The
value shown on this chart,
and thus the LBD Risk for
this MMH job, is 66%.
A closer examination of the
charts in Figure 44 and
Figure 45 shows which
factors most contributed to
the job summary values
presented in Figure 46.
Each of the five risk model
factors is discussed
separately.
Lift Rate. The lifting
frequency for the entire job
was calculated to be 420
lifts per hour. Because this
variable is composed of the
total number of lifts from
both tasks, this value is
shown to be the same on all
charts in Figures 44, 45,
and 46. As indicated by the
length of the Lift Rate bar
on these charts, this rate is
very rapid and is
comparable to some of the
highest frequency MMH
jobs previously found in
industry.

Figure 45. LBD Risk chart for the frozen food packager job, for the
Load Full Box onto Pallet task.

Figure 46. LBD Risk chart for the frozen food packager job,
computed across both job tasks.

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Average Twisting Velocity. The amount of twisting velocity required for package loading was fairly
low, but it was moderately high for the palletizing task, as can be seen by comparing Figures 44 and 45.
The greater value of the two is used in the job summary chart (Figure 46), which was determined from
the palletizing task.
Maximum Moment. As shown on the charts in Figures 44 and 45, the moment values were very low for
both tasks that comprise this job. The low weight of the individual packages (each at one pound) and
the fully packed box being palletized (12 pounds) generated low Maximum Moment values. The greater
moment value from the palletizing task was used in the job summary chart (Figure 46).
Maximum Sagittal Flexion. The package-loading task was performed while employees were in
relatively upright postures. This is reflected in Figure 44 by a short sagittal flexion bar on the chart.
However, during box palletizing, those boxes placed on the lower layers of the stack required more
forward trunk flexion. Figure 45 depicts the larger angle by the longer bar for this factor. Subsequently,
this higher value of the two tasks resulted in it being used in the job summary chart (Figure 46).
Maximum Lateral Velocity. The iLMM determined that the lateral velocity generated during the
package-loading task was actually higher than that found during box palletizing. While the values for
the previous factors all were larger during handling of the full box, and thus were used in the job
summary chart, it is the lateral velocity value from the package loading task that is used in the job
summary, since it is the greater of the two tasks analyzed.

The primary goal of the iLMM analysis


could be simply to determine whether
or not a job presents a risk of LBD to its
employees. This can be determined by
calculating the LBD Risk value from a
job summary. As Figure 47 shows,
there is some overlap in risk values
among jobs defined as low and high
risk. However, Dr. William S. Marras
and his colleagues (WS Marras, SA
Lavender, S Leurgans, S Rajulu, WG
Allread, F Fathallah, and SA Ferguson,
The role of dynamic three-dimensional

LBD Risk Value Category

It is the job summary value of 66% (taken from the chart in Figure 46) that represents the LBD Risk for
this example food processing job. The value indicates that, on the continuum of low risk jobs (0%) to
high-risk jobs (100%), this particular job has a 66% likelihood of being considered "high risk." As
stated earlier in this chapter, a high-risk job was defined as one having twelve or more (with an average
of 26.4) LBDs per 200,000 hours (or 100 full-time employees/year) of employee exposure. Results here
could be interpreted as indicating that
this particular job has a high chance of
producing a large number of LBDs

91among employees who perform this


81-90%
job.
71-80%
61-70%
51-60%
41-50%
31-40%
21-30%
11-20%
0-10%
0

10

15

20

25

30

Percent of Jobs
Low Risk Jobs

High Risk Jobs

Figure 47. Distribution of the LBD Risk values for jobs


defined as low risk and those defined as
high risk in Marras et al. (1993).

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trunk motion in occupationally-related low back disorders: the effects of workplace factors, trunk
position and trunk motion characteristics on injury, Spine, 18(5):617-628, 1993) found that those jobs
with fairly low LBD Risk values (below 30%, for example) were much more likely to have few LBDs
associated with them. Similarly, very few jobs having a risk value over 50% were defined as low risk,
and no low-injury jobs had LBD Risk values over 70%. That is, jobs with LBD Risk values above 60%
are virtually assured to have some LBDs associated with them.
A second goal of the analysis may be to compare one job task with another, to determine which one(s)
require more back motions and external moments about the trunk. This exercise can assist in learning
what task(s) should be the focus of redesign efforts. Introducing ergonomic modifications to tasks
already found to have low LBD Risk values probably will have little real impact on improving the job
overall. However, making changes to tasks whose individual factors contribute most to the job's
summary LBD Risk value will reduce the risk associated with the entire job.
A third goal of the analysis may be to determine, for specific tasks, what individual components are
most responsible for its composite probability value. This type of analysis provides direct information
regarding how the job's requirements may affect those factors used in this probability model. Examples
of ergonomic improvements that can be made on a job to affect each component are listed below. These
examples should not be considered an exhaustive list of possible changes that can be implemented to
improve working conditions.

Interpreting Results from Several Employees


Casual observation of any material handling activity will show that different people usually perform the
same job slightly differently. Employees inherently vary in how they perform manual work, and this
will likely produce different trunk motions. To account for these differences, the investigator may wish
to use the iLMM to monitor several employees who perform the same job and then analyze and interpret
the results in terms of average probabilities across these employees. Research has indicated that for jobs
and tasks where the activities do not vary from trial to trial (e.g., start and finish heights), that with a
minimum of three employees monitored, as few as three trials for each task are necessary to account for
the variability in the job (Allread et al. 2000). However, for tasks that are more variable (e.g., start and
finish heights vary from trial to trial, as well as the weight of the load), the authors know of no literature
that specifies how many employees must be monitored to account for all variability in a job. This
process is task-dependent, and the investigator should study the amount of variability of the job tasks
and work layout before deciding how many employees to monitor. Assembly-line or machine-paced
operations may limit the freedom employees have in performing job tasks in comparison with self-paced
MMH work. The investigator may want to adjust the number of employees monitored accordingly.

Approaches to Intervention
Addressing Lift Rate. The total number of material handling actions required of the job affects this
risk factor. Thus, reducing this rate will reduce the overall risk value. Management may not favor this
type of change, since it will likely reduce productivity. However, there are ways to redesign jobs to
reduce lifting frequency:

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(1) Rearrange Job Tasks. For jobs in which a number of tasks comprise the job, one method is to
rearrange tasks with those of other jobs. This may more evenly distribute the lifting frequencies
of several jobs, some of which may be considerably lower than the job monitored.
(2) Rotate Jobs. Rotating employees between jobs having high lifting frequencies with one having
much lower frequencies also will reduce the lift rate for the job of interest. The effects of the
job(s) into which employees are rotated must also be considered, however. It should be
cautioned that this and the previous approach are most beneficial if the jobs that are rearranged
or included in the rotation allow employees to use different muscle groups to perform the job.
Rotating employees into jobs that require the same muscles be used likely will have either no
benefit or could produce greater musculoskeletal stress.
(3) Add Employees. Dividing the job so that added personnel are available to perform the job will
distribute the work across more employees and lower the job's required per-person lift rate. Of
course, the cost of the additional employee(s) must be compared with the benefits of reduced
LBDs and their related costs.
(4) Automate. It may be possible that some job tasks can be automated through new equipment,
processes, or use of robotics. This method of assisting the material handler will undoubtedly
reduce the lifting frequency of the job and the overall job requirements.
Addressing Average Twisting Velocity. Rapid twisting of the trunk can result from a number of
situations. If a work area is designed such that material transfer from point A to point B is difficult or if
these two locations are not convenient to one another, rapid trunk twisting may result. High velocities
sometimes result from work areas that do not allow employees to move their feet to handle goods. As a
result, an employees turning action that would normally include movement of the trunk, hips, legs, and
ankles is more concentrated in the trunk, and higher twisting velocities can occur. It would be difficult
to reduce the speed at which employees twist simply by instructing them to slow down. However,
engineering controls that can reduce twisting velocity include:
(1) Place Work in Front of Material Handler. Move the locations of point A relative to point B, so
that they are more convenient to one another. In other words, create a workplace in which the
MMH requires moving in as few planes of motion as possible, thus allowing the employee to
remain is a more neutral posture.
(2) Spread Out Congested Work Areas. Material handling areas that allow employees to walk or
take at least one step between handling points A and B often reduces the trunk twisting velocity
required of the job. This occurs because the added movement allows one to get into a position in
which the entire body can assist in the transfer, rather than just the trunk.
(3) Raise Working Heights. Depending on the location of goods to be handled, lower levels of work
that require a great deal of sagittal flexion also may require additional trunk twisting. This is
often the case when the work requires asymmetric lifting. By raising the work heights, not only
will forward flexion by reduced, but twisting velocity can decrease because the handling
distances are more appropriately located.

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Addressing Maximum Moment. Because an external moment is the product of an object's weight and
the distance from the body at which it is handled, reducing either of these two factors will reduce the
moment. Various examples are described below.
(1) Reduce Weight Requirements. Some work situations allow employees to handle as many units
or as much weight as they feel is acceptable. However, to work faster, some employees may
handle more goods at one time than is physically safe. A limit on the numbers/weights of objects
handled in any given time can reduce Maximum Moment values. In some environments, raw
materials handled are received from a supplier in bulk quantities. The weights of these materials
may produce excessive moment values. By working with these suppliers, an arrangement may
be possible to package materials in smaller, lower weight containers. The weight changes just
described likely will increase the lifting frequency of the job, however, so this trade-off in the
LBD Risk model should be examined.
(2) Install Material Handling Equipment. For goods that are of uniform shape or size, several types
of lifting aids are commercially available to provide handling assistance. These can be adapted
to a wide range of work environments. Handling aids, such as lifting hoists, when incorporated
successfully, greatly reduce the loading forces on the spine and result in much lower Maximum
Moment values. The device chosen should be considered carefully, since a handling device that
is difficult to use or greatly slows the job process will likely be abandoned by the employees. In
addition, some material handling equipment can reduce the distance at which objects are
handled. For example, many types of lift/tilt tables are available commercially and able to be
adapted to specific needs. These devices can raise or angle objects or bins of goods so that they
can be more easily accessed by employees. This can result in reduced horizontal reach distances.
(3) Evaluate the Transfer Locations. The distance from the body at which an employee handles
goods often is greatest during the initial or final contact with the product. This may be true
especially during palletizing operations, in which items need to be placed properly on a skid to
ensure the loads stability. During carrying, for example, people tend to bring the load closer to
their bodies. An evaluation of these locations may identify workplace arrangements that cause
employees to reach further than is necessary to handle objects.
Addressing Maximum Sagittal Flexion. The more employees work in upright positions during MMH,
the lower their trunk flexion will be. This reduces subsequent LBD Risk jobs. Reducing sagittal flexion
can be accomplished by eliminating tasks that, for example, require loads to be handled below knee
level. Several interventions can prevent these situations.
(1) Raise the Heights of Loads Placed near the Floor. Objects can be raised from the floor during
MMH a number of different ways. For palletizing tasks, stacking unused skids underneath the
pallet will raise the height of the bottom-most objects. Lift tables and other equipment placed
underneath objects also will raise objects higher off the floor and reduce sagittal flexion. These
changes should be evaluated for safety considerations and to ensure that objects at the top of the
pallet can still be accessed. Other tables are available commercially that tilt or swivel objects,
such as those on pallets, that bring the loads closer to employees.

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(2) Adjust Working Heights Relative to an Employee's Standing Height. Work areas that are
adjustable to accommodate those performing the work also can reduce trunk flexion. Work
tables can be constructed or purchased that move vertically to a position most comfortable to the
user. On assembly lines, conveyors can be adjusted that raise or lower objects depending on the
work being performed at a specific location. Alternately, work areas alongside the lines, under
the employees themselves, can be raised or lowered to produce the correct working height.
(3) Train Employees on Proper Lifting Techniques. For some work situations, vertical adjustability
may not be technically or economically feasible. In these cases, employees can be educated on
proper lifting techniques aimed to reduce back strain and reduce the amount of sagittal flexion
required.
Addressing Maximum Lateral Velocity. High lateral velocity values on the risk charts indicate that
the MMH requires rapid sideways bending of the trunk. This motion may be difficult to visualize, but it
usually indicates that work is not being performed in front of one's body, but asymmetrically instead.
Workplace modifications that more conveniently locate or raise the work relative to the material handler
(as already noted above) can assist in reducing this factor on the probability charts. One specific
example (C Stuart-Buttle, A Case study of factors influencing the effectiveness of scissor lifts for box
palletizing, American Industrial Hygiene Association Journal, 56(11):1127-1132, 1995) found that
reductions in lateral velocities and sagittal flexion can be achieved through workplace interventions in
MMH tasks using lift tables. This paper also illustrated the importance of testing the impact of
workplace modifications. The initial installation of this table actually produced higher iLMM risk
values and more employee dissatisfaction. The iLMM analysis identified the problems with the new
system and provided feedback about how the workplace needed to be further changed to produce actual
risk reduction.
From the example job modifications discussed above, it is important to understand that these five
workplace factors are inter-related. None of these factors respond independently from the others. For
instance, adding a lift table to palletizing work may reduce sagittal flexion, because the load is being
raised. However, is also can lower the Maximum Moment and Average Twisting Velocity values,
because the load may be held closer to the body during handling and be more easily accessed . If the
work is self-paced, Lift Rate actually could increase since the work may be less physically demanding
and those affected may be capable and willing to handle more material. This example illustrates the
trade-offs that must be considered when evaluating the probability of risk for a job and implementing
ergonomic interventions.

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Chapter 6 Maintenance
Battery Charging
The iLMM batteries can be recharged using the AA
battery charger and its power cord (Figure 48), located
in the iLMMs computer tray. To charge batteries,
secure the units power cord and plug into a 110 VAC
wall outlet. Place up to four AA batteries into the
charger, in the orientation marked on the charger itself.

To 110 VAC
Wall Outlet

AA batteries

Each charging compartment has its own LCD display,


which indicates the selected mode and charging rate,
elapsed charging time, the batterys full capacity and
voltage, and when battery charging has completed.
The charger has four modes charge, discharge,
refresh, and test which can be used simultaneously in
each battery compartment.

Battery charger

Figure 48. AA batteries and charger.

Charge/Discharge Mode. All charge is removed from


the battery (which can reduce the memory effect). The battery then recharges, reaching a more
beneficial capacity.
Refresh Mode. Is the best mode for use with older rechargeable batteries. Batteries are cycled between
discharge and charge, until optimal capacity is reached.
Test Mode. Measures the batterys capacity. A battery is fully charged and then discharged. Three
charging rates are available. The 700 mA and 500 mA rate settings can charge AA batteries faster than
the 200 mA rate setting. This slower setting charges an AA battery in about 13 hours. However, this
setting is recommended to prolong battery life.

iLMM and Cable Care


An industrial environment can put heavy wear on the iLMM system. To preserve the integrity of the
iLMM and cables used with it:

When possible, protect the iLMM from dust, dirt, and liquids.
Remove any dust, dirt, or liquids from the system as soon as possible.
Keep the iLMM on its storage plate, covered in the case, when not being used.
Route cables so that they will not be run over by equipment in the area, be stepped on, or present a
tripping hazard.
When connecting and disconnecting cables, never pull on a cable to loosen a connection. Instead,
pull on the connector itself.
Tie a loop in the cables used, to provide strain relief.
Periodically check the condition of cables to detect signs of wear, such as frayed wires.
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Chapter 7 Reference
Troubleshooting
This section explains how to identify and resolve problems related to your iLMM system.
Pressing the Wrong Function Keys. Periodically, the incorrect Function key may be pressed during
data collection. When this occurs, the trial data will be assigned to a different task than the one
intended. Two scenarios are possible. These are described below.
(1) If an undefined Function key is inadvertently pressed during data collection in a trial, two remedy
options are possible.
The data collection session can be closed and not saved. However, all data from the trials
collected in the Run will be lost.
Data collection can continue, using the same undefined Function key for the remainder of the
Run. After data collection for the Run is completed and saved, a New Task definition screen
will appear, prompting the user for task definition input such as task name, description,
moment-arms, etc. If the input data vary from trial to trial (e.g., moment arms), these data can
be left blank when defining the new task and filled in on a trial-by-trial basis following data
collection.
(2) If a pre-defined Function key was inadvertently pressed during data collection, the user can:
Stop the data collection session and not save the data for the Run. However, all data from the
trials collected in the Run will be lost.
Finish collecting the trial data by pressing the same (incorrect) Function key and noting which
Trial number(s) and Run number(s) this particular data correspond to. After the data are saved,
the Data Editing options can be used to either delete the trial(s) from the database or rename
them from the list of pre-defined task names.

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Technical Support
NexGen Ergonomics, Inc maintains technical support, weekdays (excluding major holidays) from 9am
to 5pm Eastern Standard Time. If there is difficulty with the system that cannot be resolved using this
Operators Manual, feel free to contact NexGen Ergonomics for further assistance:
NexGen Ergonomics, Inc
6600 Trans Canada Highway, Suite 750
Pointe Claire, Quebec H9R 4S2 Canada
Phone: 514-685-8593
Fax: 514-685-8687
Email: techsupport@nexgenergo.com

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Accessories, Supplies and Services


ACUPATH Industrial Lumbar Motion Monitor
Includes:
Storage/ Shipping/Field Desk Case

Part No. FA-0101

iLMM System
iLMM Upper Component
iLMM Lower Component
iLMM Radio
iLMM USB Radio, with 5 ft Cable
iLMM Cable Connector
USB-to-LMM Cable
USB Extension Cable, 30 ft

Part No. FA-0109


Part No. FA-0108
Part No. FA-0105
Part No. FA-0104
Part No. FA-0115
Part No. FA-0112
Part No. FA-0107

Rechargeable Batteries (8 per unit)


Battery Charger, with Power Cord
Radio Repositioning Plate

Part No. FA-0111


Part No. FA-0110
Part No. FA-0106

Shoulder Harness
Waist Belt

Part No. FA-0103


Part No. FA-0102

Operators Manual
BALLET 2.4 Software CD

Part No. FA-0114


Part No. FA-0113

Optional Training and Service:


1-Day Training Seminar
Service Agreement (per year)

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End-User License Agreement


This End-User License Agreement applies to Biodynamic Solutions ACUPATH iLMM BALLET
2.4 software.
This End-User License Agreement (EULA) is a legal agreement between you, the Customer, either an
individual or a single entity, and Biodynamic Solutions for the software products identified above which
may include associated software components, media, printed materials, and online or electronic
documentation (Software Product).
By installing, copying, or otherwise using the Software Product, you agree to be bound by the
terms of this EULA. If you do not agree to the terms of this agreement, do not install or use this
Software Product.
The Software Product is protected by copyright laws and international copyright treaties, as well as other
intellectual property laws and treaties. The Software Product is licensed, not sold.
1.

Grant of License. The Software Product is licensed as follows: Biodynamic Solutions, Inc grants
you, the Customer, the right to install and use a single copy of the Software Product. You may also
make a copy of the Software Product as may be necessary for backup and archival purposes.

2.

Description of Other Rights and Limitations. You must not remove or alter any copyright
notices on the Software Product or on any copies thereof. You may not distribute copies of the
Software Product to third parties. You may not reverse engineer, decompile, or disassemble the
Software Product. You may not rent, lease, or lend the Software Product. You may permanently
transfer all of your rights under the EULA only if you are permanently transferring your rights to
the Biodynamic Solutions, Inc equipment or products with which the Software Product was
delivered and provided that the recipient of the Biodynamic Solutions, Inc equipment or products
delivers to Biodynamic Solutions, Inc the recipients written agreement to be bound by the terms of
this EULA. Biodynamic Solutions, Inc may provide you with support services related to the
Software Product (Support Services). Use of Support Services is governed by the Biodynamic
Solutions, Inc policies and programs described in the Operators Manual, in online
documentation or other Biodynamic Solutions-provided materials. Any supplemental software
code provided to you as part of the Support Services shall be considered part of the Software
Product and subject to the terms and conditions of this EULA. With respect to technical
information you provide to Biodynamic Solutions, Inc as part of the Support Services, Biodynamic
Solutions, Inc may use such information for its business purposes, including for product support
and development. Biodynamic Solutions, Inc will not utilize such technical information in a form
that personally identifies you. You must comply with all applicable laws regarding use of the
Software Product.

3.

Termination. Without prejudice to any other rights, Biodynamic Solutions, Inc may terminate this
EULA if you fail to comply with the terms and conditions of this EULA. In such event, you must
cease all use of the Software Product and destroy all copies of the Software Product.

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4.

Copyright. All title, including but not limited to copyrights, in and to the Software Product and
any copies thereof are owned by Biodynamic Solutions, Inc or its suppliers. All rights not
expressly granted are reserved by Biodynamic Solutions, Inc.

5.

U.S. Government Restricted Rights. The Software Product is provided with Restricted Rights.
Use, duplication, or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c) (1) (ii) of the Rights in Technical Data and Computer Software clause at DFARS
252.227-7013 or subparagraphs (c) (1) and (2) of the Commercial Computer Software Restricted
Rights at 48 CFR 52.227-19, as applicable. Manufacturer is Biodynamic Solutions, Inc, 330 W
Spring St, Suite 205, Columbus, OH 43215.

6.

Export Restrictions. You agree that you will not export or re-export the Software Product to any
country, person, entity or end user subject to U.S.A. export restrictions. Restricted countries
currently include, but are not necessarily limited to Cuba, Iran, Iraq, Libya, North Korea, Sudan,
and Syria.

7.

No Warranties. The Software Product and any related documentation is provided As Is and
Biodynamic Solutions, Inc expressly disclaims any warranty for the Software Product.
Biodynamic Solutions, Inc makes no warranty, express or implied, as to any matter
whatsoever, including without limitation any warranty of merchantability or fitness for a
particular purpose except those set forth in the description and directions on the labeling of
the equipment. Unless the equipment is used in accordance with the directions on the labeling
and the instructions accompanying the equipment, this limited warranty and any warranties
in such description shall be void and of no effect. The entire risk arising out of use or
performance or the Software Product remains with you.

8.

Limitation of Liability. Biodynamic Solutions, Inc shall have no liability for any
consequential, incidental, or special damages by reason of any act or omission or arising out
of or in connection with the equipment or its rental, delivery, installation, maintenance,
operation, performance, or use, including without limitation any loss of use, lost revenue, lost
profits, or cost associated with downtime. In any case, Biodynamic Solutions aggregate
maximum liability under any provision of this EULA shall be limited to the amount actually paid
by you, the Customer, for the Software Product.

9.

Governing Law. This Limited Warranty shall be governed by, and construed and interpreted in
accordance with, the local laws of the State of Ohio (without application of its conflicts of laws
rules).

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Limited Warranty
Sale of ACUPATH iLMM Equipment
This Limited Warranty applies to the ACUPATH iLMM equipment, which consists of the Case, the
Computer Tray, the Device Tray with Zero-plate, the USB Radio, eight Batteries, the 5 ft serial
communications cable, the ACUPATH iLMM device, the Battery Charger, the Shoulder Harness,
the Waist Belt, and the 30 ft data cable (Equipment) and does not apply to related software. The
BALLET Software is covered by the ACUPATH iLMM End-User License Agreement.
1. Warranty of Title. Biodynamic Solutions, Inc warrants solely to the original purchaser
(Customer) that (a) Biodynamic Solutions, Inc has good title to the Equipment and that, upon
Customers payment of the purchase price to Biodynamic Solutions, good title to the Equipment will
be transferred to Customer and (b) the Equipment when delivered to purchaser will not infringe the
valid United States patents of any third party.
2. Limited Warranty of Condition and Operation. Biodynamic Solutions, Inc warrants solely to
Customer that when delivered to purchaser and for a period of one (1) year after the date of delivery
to Customer, the Equipment, will conform in all materials respects to Biodynamic Solutions
published specifications when used as described in Biodynamic Solutions written instructions, be in
good working order and free of defects in workmanship and materials. Except as otherwise
provided herein, Biodynamic Solutions, Inc makes no warranty, express or implied, as to any
matter whatsoever, including without limitation any warranty of merchantability or fitness for
a particular purpose except those set forth in the description and directions on the labeling of
the equipment. Unless the equipment is used in accordance with the directions on the labeling
and the instructions accompanying the equipment, this limited warranty and any warranties in
such description shall be void and of no effect.
3. Customers Exclusive Remedies. If within one (1) year from the date of delivery to Customer the
Equipment does not comply with the foregoing Limited Warranty of Condition and Operation,
Biodynamic Solutions will at its option, repair, replace or refund the purchase price of the defective
Equipment free of charge to the Customer. Customers requesting repair, replacement or refund are
required to ship, at Biodynamic Solutions expense, the Equipment to Biodynamic Solutions, Inc at
its facilities in Columbus, Ohio, or at such other place as Biodynamic Solutions designates. As a
condition of this warranty, Customers must call Biodynamic Solutions Customer Service Line for
instructions on and prior approval of shipment prior to returning any defective Equipment.
4. Limitation of Liability. Biodynamic Solutions, Inc shall have no liability for any
consequential, incidental, or special damages by reason of any act or omission or arising out of
or in connection with the equipment or its rental, delivery, installation, maintenance,
operation, performance, or use, including without limitation any loss of use, lost revenue, lost
profits, or cost associated with downtime. The obligations contained in this paragraph
continue beyond the term of this limited warranty.
5. Governing Law. This Limited Warranty shall be governed by, and construed and interpreted in
accordance with, the local laws of the State of Ohio (without application of its conflicts of laws
rules).

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Index
30 ft Data Cable ................................................................................................................................ 4, 5, 59
6 ft Serial Communications Cable .................................................................................................... 4, 5, 59
ACUPATH .................................................................................................... 1, 2, 4, 8, 16, 44, 59, 60, 62
Average Twisting Velocity ..................................................................................................... 39, 51, 53, 55
BALLET ........................................................................... 1, 4, 10, 13, 14, 16. 22, 44, 46, 49, 59, 60, 62
Battery ...................................................................................................................... 4, 5, 6, 7, 8, 56, 59, 62,
Battery Charger ..................................................................................................................... 4, 5, 56, 59, 62
Company [software variable] .................................................. 14, 16, 17, 18, 19, 20, 25, 26, 32, 34, 35, 48
Cross-Your-Heart ...................................................................................................................................... 10
Employee [software variable] 14, 16, 17, 19, 20, 25, 32, 34, 35, 37, 39, 48,
Industrial Lumbar Motion Monitor/iLMM ...........................................................................................
...................................................... 1-14, 16, 17, 19, 34, 35, 37, 44, 45, 47, 49, 51, 52, 55-57, 59, 60, 62,
Job [software variable].............................................. 14, 15, 16, 17, 18, 19, 20, 25, 26, 334, 35, 37, 39, 48
Lift Rate .......................................................................................................... 17, 26, 43, 46, 50, 52, 53, 55
Lifting Index (LI) ................................................................................................................................ 18, 22
Low Back Disorders ...................................................................................................................... 2, 13, 52
Manual Materials Handling (MMH) ..... 2, 13, 16, 17, 26, 35, 36, 37, 44, 45, 46, 47, 49, 50, 52, 53, 54, 55
Maximum Lateral Velocity ..................................................................................................... 18, 39, 51, 55
Maximum Moment ........................................................................................................... 46, 47, 51, 54, 55
Maximum Permissible Limit (MPL) ............................................................................................ 18, 19, 22
Maximum Sagittal Flexion ........................................................................................................... 39, 51, 54
NIOSH .................................................................................................................................... 13, 17, 18, 22
Project [software variable] ........................................................................ 16, 19, 20, 25, 26, 32, 34, 37, 39
Psychophysical ........................................................................................................................ 16, 18, 22, 26
Radio Repositioning Plate............................................................................................................. 4, 5, 8, 59
Recommended Weight Limit (RWL) ................................................................................................. 18, 22
Report........................................................................................................................................................ 22
Service Agreement .................................................................................................................................... 59
Shoulder Harness .......................................................................................... 4, 5, 10, 11, 12, 35, 47, 59, 62
Storage Plate ......................................................................................................... 4, 7, 9, 10, 11, 12, 34, 56
Task [software variable] ......................................................... 14, 16, 17, 18, 19, 20, 25, 26, 35, 36, 37, 39
Telemetry ........................................................................................................................................ 8, 10, 16
Training Seminar ...................................................................................................................................... 59
USB Radio .............................................................................................................................. 4, 5, 8, 34, 59
USB-to-LMM Cable ............................................................................................................................. 4, 59
Waist Belt................................................................................................ 4, 5, 11, 12, 34, 35, 45, 47, 59, 62

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Notes

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