Ergonomics Basics For Workplace Design

C/MP - Manufacturing Coordination, Production System
Development and Investment

Planning – Industrial Engineering C/MPS3
Ergonomics basics for

workplace design
IE/MZ006
Manual
1 C/MPS3 | 07.2010 | © Alle Rechte bei Robert Bosch GmbH, auch fü r den Fall von Schutzrechtsanmeldungen. Jede Verf ügungsbefugnis, wie Kopier und
Weitergaberecht, bel uns.
C/MPS3 Ergonomics (IE/MZ006)

Ergonomics I - Overview
Ergonomics basics for

workplace design
IE/MZ006
C/MPS3

Ergonomics I - Overview
Overview
 Introduction
 Body measurements
 Body postures
 Workplace measurements
 Reach range and field of vision
 See and illuminate
 Physical strength
 Ergo Check

Ergonomics basics for workplace design
1. Introduction


Ergonomics I - Introduction
Ergonomics

Ergonomics
Study of people’s efficiency in their working environment
•Adaptation of work environment to the human
•Adaptation of tools, workplaces, organization to the human
In order to
•Minimize physical and psychological hazards
•Keep performance capability and willingness
Adaptation to the human

•Capabilities (effort, body heights…)
•Professional/manual skills (experience, education…)
•Necessities (social criterias…)

Physical strain - stress

External influences on human
Adaptation of
Adaptation of
work to human
environment to
human
Physical and mental

capacities and aptitude

What has to be designed ergonomically?

Tool hanger
Illumination
Spring pull
Info board
Material level
Power strips
Part bins
Tool shelf
Work table Fixture
Case lifter Work chair
Footrest

Physiology Organization Environment
Effort Cyclic work Illumination

Speed of movement Work structure Noise
Precision Breaks organizaition Climate
Body posture Working forms Colors
Aspects of the workplace design
Information Anthropometrics Laws
Operational Elements Working heights Safety

Display Reach range ArbeitssicherheitsG
Tools (Software) Field of vision Arb StättV
Perception Movement area BGV

Bosch Norm N51M M20
4 497 010 554 2009-01-16
BOSCH General delivery instructions for machinery, installations and production N51M
NORM equipment (MAE) M20
Allgemeine Liefervorschriften für Maschinen, Replaces edition 2008-10-30

Anlagen und Fertigungseinrichtungen (MAE)
Property of Robert Bosch GmbH
In case of doubt apply the German version of this Bosch-Norm.
1 General 　
Bosch-Norm N51M M20 is valid and binding for all machine types within the EG. For all other regions adoption of N51M M20 is
recommended. For implementaton the nation-specific rules and legislation must be complied with. On principle deviations from N51M M20
are to be coordinated with the respective lead plant.
The following standards, Bosch-Norms and guidelines are to be complied with, each in the version valid at the time of accepting the order:
- Electrical equipment in accordance with DIN EN 60 204-1 and Bosch-Norm N51M M23
　
- for special purpose machines additionally Bosch-Norm N54
- Hydraulic and pneumatic equipment as separate units as well as components of machines, based on Bosch-Norm N51M M25 and/or N51M
M26
- Basic safety- and health requirements based on EG-Machinery Directive RL 98/37/EG
"The new EG-Machinery Directive 2006/42/EG will be effective per 2009-12-29 and supersedes 98/37/EG."
- Requirements from legal regulations on occupational health, fire and environmental protection
- Independent compliance with the requirements also for assembly work at our locations
　
- Workplace design and dimensioning based on ergonomic aspects per N62A 3.3 (s. Intranet page C/MPS)
- Layout of workplace with Visual Display Units based on N2588 (valid only for Germany) 　 Intranet
The supplier accepts the obligation to comply with these requirements. Deviations with our approval have to be remedied by the supplier free of costs
for us.
C/MPS3
The cooperation of the orderer in the technical solution or the approval of construction features do not exempt the supplier from their sole responsibility
for flawless function, neither do they limit the assured properties.
12 Internal | AA/QMM-PMI-Q | 28/02/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as
well as in the event of applications for industrial property rights.
4 497 026 617 March
Bosch Norm 2006
BOSCH General delivery instructions for machinery, installations and N51M
N93 A11 NORM production equipment (MAE) M20
1 General
Hazard assesments are performed in order to detemine and evaluate potential hazards at the workplace for the health and
safty of employees, they are the basis for deciding on required protective measures.
Property of Robert Bosch GmbH 2 Scope

This Bosch-Norm is binding for Bosch, TOGE affiliates, excluding RBI. = RB Inland
3 Terms
Source of, or situation that may lead to damage, e.g. An injury or an illness caused by
-Mechanical
-Electrical
-Hazardous-ralated hazards
- Hazard 　 -Hot and cold-related media

-Biological
-Aggravated working conditions
-The combined effects of work and production methods, work sequences and working hours
-Other hazards.
- Risk assessment Method to identify hazards and define their characteristics.
- Hazard assessment Identify and evaluate potential cause that may lead to accidents and health impainment.
Places and areas where activities take place and working materials (e.g. Materials such as
- Workplaces accessories, operating materials, hazardous materials, packaging materials) are used, as well as
working equipment (e.g. Machines, installations, equipment (MAE), devices and tools.
Bosch Norm N93 A11

4 Performance
4.1 Responsibility
Workplaces shall be assessed with regard to their hazards. Assessment takes into account the operation equipment that exists at the workplace
and the working materials, the working methodology and the working environment as well as the relevant operation conditions, in particular
regular operation, maintenance and the investigation of irregularities.
Responsibility for performing and renewing hazard assessment lies with the superior (operator) who is responsible for the workplace, and
who also represents the employer, who is by nature and as a rule, the site-foreman or the department head.
4.2 Implementation
Those employees influenced have to be involved in a suitable manner. Responsible departments (e.g. HSE, WAR) and technical departments
(e.g. TEF, FCM) support where required to do so.
For new MAE and building investments, an overall final acceptance process at the plant level has to be set up, carried out and documented.
The pre-operational safety inspection by HSE – with reference to compliance with the required occupational health/safety, fire and
environmental protection – is part of this process (see N93 S1).
4.3 Reasons
Possible reasons for performing a hazard assessment are e.g.:
-Assessment of existing and/or new workplaces (“initial assessme4nt”),
-Use of new and/or significantly changed working equipment, materials and methods,
-Accidents, occupational diseases, illnesses that occur frequently and other occurrences for which work-related causes may be assumed.
In the case of similar workplaces with comparable hazards, the assessment of one representative workplace is sufficient.

2. Body measurement

Ergonomics I – Body measurement
Standardized
population
Real population

Body height and percentile
Frequency
90%
Percentile
95% 99%
1% 5% 50%

Body height and percentile in Germany
Male Percentile 1M 5M 50 M 95 M 99 M
♂ Body height 158 165 175 185 189 cm
Male Percentile 1F 5F 50 F 95 F 99 F
♀ Body height 147 153 162 172 176 cm
Source: DIN 33402, Dec. 2005

Body height and percentile in Europe
Percentile 5M 50 M 95 M
“Average European”
Body height (in cm) 153 172 188
Source: Arbeitswissenschaftliche Erkenntnisse Nr. 108.

International Anthropometric Data, Hrsg. Baua, 1998
Body measurements further countries

Nationalities ♀ Female [m] ♂ Male [m] Age Year
5F 50 F 95 F 5M 50 M 95 M
Poland 1501 1587 1667 1627 1730 1821 18-60 1984
France 1510 1590 1700 1590 1700 1810 1982
Spain 1430 1590 1710 1530 1650 1770 1978
USA 1511 1615 1720 1636 1748 1853 18-65 1973
UK 1478 1608 1737 1580 1709 1839 1973

Japan 1438 1537 1636 1575 1669 1763 1973
Canada 1455 1577 1699 1608 1727 1847 1973
Past Yugoslavia 1473 1582 1683 1632 1741 1849 18-40 1986
Pygmies 1360 1410 18-30 1950
China (Yangste Fluss) 1560 1670
China (Si Chuan) 1530 1630
Russia 1508 1595 1680 1614 1723 1832 18-21 1977
Lithuania 1570 1651 1731 1672 1768 1864 18-21 1977
Example of use of the body measurement values
Range in front of (Grasp axis), Measure Nr. Body depth, standing, measure Nr.1.2
1.1 (Table 21) (Table 10)
Male Female Male Female

Percentile Percentile Percentile Percentile
5. 50. 95. 5. 50. 95. 5. 50. 95. 5. 50. 95.
Age (18 to 65) 685 740 815 625 690 750 260 285 380 245 290 345
Source: DIN 33402, Dec. 2005

3. Body postures
Ergonomics I – Body postures
In the ideal case, which components should be adapted by the

operator?
Energy expenditure according to posture and type of work

Variation of work Work energy
Posture energy expenditure Type of work Degree expenditure
(KJ/min)* (KJ/min)
Rest 0 NO muscle work 0
Low 1.0-2.5
Sit 1
Hand work Medium 4.0-5.5
Stand 2.5 high 2.5.-5.0
Low 5.0-7.5
Stand bent 4.0
1-arm work Medium 7.5-10.0
Knee 3.0 high 6.0-8.5
Low 8.5-11.0
Walk 4 km/h (without load) 14.1
2-arms work Medium 11.0-13.5
Walk 4 km/h (with load, for
28 high 11.0-17.0
example beer crate 21 kg)
Low 17.0-25.0
* In comparison to resting position
Body work Medium 25.0-35.0
Source Spitzer et al., 1982
high 35.0-50.0
Relation between work content and body posture

Work design criteria Examples
Work with high demand of applying power Metal worker work, assembly of heavy parts, important effort ●
necessary
Work with high demand of precise motions (fine Precise works, assembly of very small parts, soldering, visual ●
motor skills) inspection
Assembly work Assembly of small and medium parts ● ●
Use of visual/optical aids Microscope workplaces, visual inspection with binocular ●

(constant work place)
Missing free room for legs Fundament under machining ●
Handling of big parts Frequent handling of parts ＞ 300×300×300mm (e.g. packaging) ●
Frequent change of the work place or necessity to Multiple use of machines, more work places than workers, ●
have a visual overview observation of the work area ( ＞ 220°)
High working position over the table top Placing in fixture 180mm (detail inspection necessary) assembly ●
in framework with height difference ＞ 300mm
Ranking of body postures

 Reduction of stress by changing the body posture
Sitting and Standing
Sitting
Increasing of
Standing and walking
strain
Standing
Physiological evaluation
Work-related and physiological criteria Stand Sit Sit and Stand
Hydrostatic blood pressure in the legs ■ □

Energy requirement for maintaining the posture ■ □
Static holding work, demand on supporting and ■ □

moving apparatus
Curbing breathing and digestion □ ■
■ High requirements Medium requirements □ Low requirements
Changing the body posture

between standing and
sitting will reduce physical
strain to the operator
Permanent standing
 Definition “permanent standing posture”
Working in standing position without the possibility to move more than 20 cm to the
side, front or back
Source: BGI Bericht 504-46 Belastung des Muskel-Skelett-Systems-Hauptverband der gewerblichen Berufsgenossenschaften
(2005-08)/6/
 Strain/Stress on
 Musculoskeletal system (static muscle work)
 Cardiovascular system
Permanent standing – Risk areas

Risk area 1 Up to 2.5 hours Low standing effort
No overstress expectable
Risk area 2 2.5 to 4 hours Elevated standing effort

Possible overstress for persons with restrictions
Measures for re-design are recommendable
Risk area 3 Very elevated standing effort

4 to 5.5 hours Possible consequences on health for normal persons
Employment ban for pregnant women after 5th month
Measures for re-design are necessary
Risk area 4 More than 5.5 High standing effort

hours Probably consequences on health for normal persons
Measures for re-design are stringently necessary
Source: Bewegungsergonomische Gestaltung von andauernder Steharbeit, Länderausschuss für Arbeitsschutz und
Sicherheitstechnik (LASI), March 2009, ISBN: 3-936415-31-5)
Stand and walk – Introduction (blue card)

 Targets
 To design an optimal relation between standing and walking in stand/walk-walk
system
 To reduce the strain of the musculoskeletal system (muscles, joints) and of the heart
rate
 Criteria
 Valid for men and women
 Application only for the relation between standing and walking
Explanations to physiological effects

 “Standing≧4s”
 Allow the recovery of muscles and joints of the musculoskeletal system
 Too long standing leads to orthostatism (accumulation of blood in legs/feet)
 “Walking” activates the veins pump with the foot motions. Consequently the blood
can be moved to the upper body.
 “Turn body” leads to a strain due to rotation in feet, knees and hip joints
Evaluation
Criteria Proportions
Relation “Standing (≧4s)” to ＜ 45% or ＞ 95% of basic time without turn body
“Basic time without turn body” 45%-55% or 85%-95%
≧55% and ≦85%
Relation “walk” to “Total ＜ 45% of total walking time without turn body
waking time without turn 45%-55%
body”
≧55%
Turn Body ＞8 time / min

≦8
Work technical criteria Personal Protection Equipment (e.g. safety shoes, insole)
as well as further utilities (e.g. standing aids, ergo mat)
All criteria must be green

Yellow is temporarily possible Deviations
must be confirmed by HSE/TEF6
Application
 By new planning, the stand-/walk-criteria must be kept. Thereby it is not relevant if
the machines are new or used.
 By a current planning, the stand-/walk-criteria must be calculated. If the proportions

are yellow or red, the plant has to determine the efforts to become green and to
decide which measures are going to be achieve.
 Redesign are either new planning or current planning
 Duplicate production lines will be consider as a new planning
 Current production lines don’t have to be redesigned to keep the stand-/walk-

criteria
Application
 Don’t calculate the criteria for all part numbers, but only for A and B types and for
the most frequent occupancy
 No calculation for exotic part numbers
 Validity: Bosch Group world wide
 The fact losses are considered as standing time, if the cycle time of each work place
is different within the production lines.
Cycle time
Tact losses are considered as standing time, because the operators have to
wait for the next part
Information for planning departments
Operator walks to next station (distance ﹥approximately 80cm)

MTM1-Analysis: TBC-, W--, (possibly 2nd TBC-)
Per way: 1-2 turn body and walk
Operator walks to next station (distance till approximately 80cm)

MTM1-Analysis: SS-C- (possibly 2nd TBC-)
Per way: 0 turn body but side step
Operator walks to opposite

MTM1-Analysis: TBC-, W--,
Per way: 1 turn body and walk
Information for planning departments
Operator uses 4 stations

Per Loop: 4-6 turn body and 4 walks
Consequence: min. cycle time = 30-45 s.

Otherwise the max. quantity of turn body will be ＞ 8x/min.

4. Workplace measurements
Work place measurements
Calculation of the optimal working height for sit and stand

workplaces
Sitting workplace
Standing workplace
Optimal working heights at sitting/standing
Work Requirements Examples Working Height
H1 (Sitting) H2 (Standing)
Percentile Percentile
5th 95th 5th 95th
F M F M F M F M
High requirements for Adjustments, Visual

-Visual control Inspections, Assembly of
-Fine biomechanical
400 450 500 550 1100 1200 1250 1351
very small parts
coordination
Medium requirements for Wiring work, Assembly

-Visual control of very small parts
-Fine biomechanical 300 350 400 450 1000 1100 1150 1250
coordination
Minor requirements for Storing,

-Visual control Packaging, Assembly of
High requirements for heavier work pieces with
-Movements for arms increased use of 250 350 900 1000 1050 1150
muscular force
Calculation of the Working height over working surface

(e.g. placing in fixture)
worktable height
A = H2 - C
Calculation of working surface height

Exercise
 Calculate the optimal working surface height for a packing workplace (only for men,
standing).
 Employees are closing cartons

(250 x 250 x 250 mm) with adhesive type
and sticking a label
Calculation of working surface height

Exercise
 Calculate the optimal working surface height for a measurement workplace close to
an assembly line. Men and women are standing for a short time on that workplace.
Employees are placing the part into a measurement fixture (Height over the working
surface: 150 mm). The measurement is processing automatically.
Comparison between sitting and standing workplaces
Different view distances to work piece and reach Adaptation of sitting height easier for all, similar view
conditions for small or tall user distances and reach conditions
Bosch Blue Card

“Blue card” according to DIN 33406
Dimensions of sit/stand workplaces
Thigh height free space Z by sitting must be considered according to DIN 33 406. Is the Working
Surface Height ＞ 850 mm, than the width for legs must be≧800 mm.
Thigh height Z is not sufficient
Possible action to increase thigh height Z
Bosch Blue Card

5. Reach range and field of vision
Ergonomics I – Reach range and field of version
Good reach range and vision condition?
Small reach range

 5. perc. Woman*
 Definition: Envelope around the elbow, which is to be
generated by the forearm
(Upper arm upright and the angel between fore and upper arm = 90°)
*is to be used for designing the outside dimensions of work places (as a rule)
Large reach range

 5. perc. Woman*
 Definition: Envelope around the shoulder, which is
to be generated by the arm
Physiologic maximal reach range

 5. perc. Woman
Use of reach ranges

Reach range Components
Small
Large
Physiologic
maximal
Components are too far away
Use of software ERGOMAS to

validate planning information
Corrective Ergonomics
M 40 B M 30 B M 20 B
1 Motion 52.0 TMU 45.9 TMU 39.8 TMU
4000 Motions 208.000 TMU 183.600 TMU 159.200 TMU
Per shift 125 Min. 110 Min. 96 Min.
Per year (250 days/year) 521 Std. 458 Std. 400 Std.
- 63 Std. - 121 Std.

Benefit - 7.9 Tage - 15.1 Tage
- ca. 13% - ca. 30%
Wiper arm-assembly, 4.000 Pc./Shift, RBBE, Tienen, 1994
Field of vision
Standing Standing comfortable Sitting comfortable (middle

sitting posture)
Inclination of head α = 0° α = 15° α = 25°-30°

Optical axis β = 15° β = 15° β = 15°
Angle of view α + β = 15° α + β = 30° α + β = 40°-45°
Use of software DPE Layout Planer to validate the angle of vision
Poor design of display to machine
Good design of display to machine

6. See and illuminate
69 Internal | AA/QMM-PMI-Q | 28/02/2012 | © Robert Bos ch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Ergonomics I – See and illuminate
Criteria
 Vision distance
 Intensity of light
 Contrast
 Glare
Modification of the aperture

Adjustment of eyes to varying densities of
Adaptation and choice of the sensitivity
illumination
of the film
Adjustment of eyes on objects at varying Variation of the distance lens

Accommodation
distances to film
Physical process
Light
Light density or
Luminance L
〔 cd/m2 〕
Intensity of light E Degree of reflection p

〔 Lx 〕〔%〕
C/MPS3 | 07.2010 | © Alle Rechte bei Robert Bosch GmbH, auch fü r den Fall von Schutzrechtsanmeldungen. Jede Verf ügungsbefugnis, wie Kopier und
Measurement
Measurement of intensity of light Measurement of density of light
Luxmeter Luminancemeter
Contrast
Contrast is the difference between the density of light of 2 surfaces.

In order to see an object, it’s necessary to have a minimal contrast to the environment
The contrast can appears by brightness, color or mixed difference.
To important contrasts lead to glare.
Contrast
Bad contrast
Good contrast
Design rules to reduce contrast differences

Environment
(periphery)
Work area
10:1
(center)
10:1
1:3
Center: main work area Periphery:

assembly line, building
Light density study
Light density
L1 = 100 cd/m2 L2
= 150 cd/m2 L3
= 80 000 cd/m2
Indirect light
2 side lights (variable)
Intensity of light (dimmable)
Mat structure and brightly table surface
Uniform light density on the table surface (890 –

1090 lx)
Contrast to recognize inspection characteristics

Lightly background Dark background
Use of different light colors by visual inspection
Workplace visual inspection with blue light (HiP)

Benefits:
 Easier and quicker identification of failure on metal
 Reduction of stress and fatigue of workers

Blue light is a complement to the workplace light to increase
quality and don’t replace the workplace lights
Blue light White light

Systems lamp SL 72/ SL 36 “Blue
colors (Light code 67)”

7. Physical strength
Ergonomics I – Physical strength
Different people …
…different tasks
Rule
 “Lastenhandhabungsverordnung”
(decree for manual handling of loads)
 Bosch approach
Use of software IGEL to calculate max. loads
Approach
 Calculation of the maximal load depending on circumstances and environment
 Comparison between maximal forces and real forces on the operators
 Evaluation
for example
□ lifting index ＞ 3 : high risk
□ lifting index 1 - 3 : medium risk
□ lifting index ＜1 : low risk
Method NIOSH – Conditions of use

 NOIOSH-Lifting Equation is gender-neutral,
meaning that 90% of the male population and 75% of the female population (85% of the working
population) are protected
 Rules
 Load ≧ 3 kg (stable object)
 2 handed work (no sitting, no kneeing, no lack of place)
 Smooth, conditions movements, without jerks
 No additional physical demands
 Horizontal grip distance ≦ 63 cm (center of the hand to center of ankle joint)
 Grip height between 0 – 175 cm
 Number of lifts ≦ 15 lifts/min.
 No holding, meaning ≦ 5 sec transfer process
 No carrying, meaning walking max. 10% of the process
 No puling/pushing
 ≦ 8 hours shift
Manual Lifting of Load – Determination of Recommended Weight Limit according to NIOSH Single Task
Observe the instructions for application of this card (refer MZ006 – Manual) Recommended Weight
Limit RWL is dependent on Reference Mass Mref, Grip Height, Vertical Lifting Height, Horizontal
Grip Distance, Trunk Rotation, Grip Conditions and Frequency of Handling.
Calculation of Recommended Weight Limit according to NIOSH Single Tasks
Department:
Operation:
Analyst:
Date:
Vertical Grip Horizontal Grip

Data related with the lifting work Trunk Rotation (Grad)
Distance (cm) Distance (cm)
Vertical Lifting A
V H Duration of
Height Frequency Rate Grip
Load (kg) total task
(cm) (Lifts/min) conditions
(Hrs)
Origin Destination D Origin Destination Origin Destination
Good/Fair/
Mref
Calculation of Recommended V RWL
Weight Limit D HM AM CM FM Poor
RWL
M M
(Least of two)
Origin RWL = 23 kg x x x x x x = kg
kg
Destination RWL = 23 kg x x x x x x = kg
Calculation and evaluation of lifting index

Load □ lifting index ＞ 3 : high risk
Evaluation
Lifting Index LI = = = □ lifting index 1 - 3 : possible risk
RWL
□ lifting index ＜ 1 : low risk
Method NIOSH – CM and Lifting Index

 Grip conditions CM Grip
Description CM
conditions
Load length≦40 cm; load height ≦30 cm; good handles or hand-hold cut-outs.
Easy to handle loose parts and objects with wrap around grasp and without excessive
Good 1.0
wrist deviation.
Load length ≦40 cm; load height ≦30 cm; and poor handles or hand-hold cut-outs
Fair or 90° finger flexion. Easy to handle loose parts and objectives with 90° finger 0.95
flexion and without excessive wrist deviation.
Load length ＞ 40 cm or, load height ＞ 30 cm; or difficult to handle parts or

Poor sagging objects or asymmetric center of mass or unstable contents or hard to grasp 0.90
object or use of gloves.
The Lifting Index is a term that provides a relative estimate of physical stress associated with a particular manual lifting task.
 Evaluation LI The following levels rate the risk of a possible health hazard:
Level of risk Meaning Color

Lifting Index
Low risk Corrective actions not recommended. The risk of an illness or an Green
＜1 injury is negligible or at a low level acceptable for the operators
under consideration.
Possible risk Implementation of corrective measures to reduce risk not Yellow

1-3 recommended. A negligible risk of injury or disease exists for the
operators in question.
High risk TO be avoided, action required to minimize the risk. Nearly all Red
＞3 workers will be at an increased risk of a work-related injury when
performing highly stressful lifting tasks.
Exercise
 Packing workplace
 Task: get the part (weight 12.5 kg) from
convey and place it in cardboard.
Conveyor is placed perpendicularly to the
workplace.
 Grip condition are fair
 Horizontal grip distance is 34 cm at the
origin and 38 cm at destination.
 Duration of total task is 8 hours
 Frequency 1 time per minute
 Questions:
1. Are the real forces less than the
recommended forces?
2. Which measures can you implement in
order to improve the workplace?
Use of standard software IGEL to calculate max. loads to be handle

manually
Concept of the software IGEL for handling of loads

Criteria Shift Load Load
duration handling holding Walk with load 1 hand 2 hands Multi task
Method (hr.) (kg) (sec.)
NIOSH ≦ 8 hr. ≧ 3 kg ≦ 5 sec. Max. 10% x x
OCRA No limit ＜ 3 kg ≦ 3 sec. x x
EN 1005-2 ≦ 8 hr. ≧ 3 kg ≦ 5 sec. ＜2m x x
≦ 5 Sec.
ISO 11228-1 ≦ 8 hr. ≧ 3 kg Without ≦ 20 m x
walking
ISO 11228-2 ≦ 8 hr. Push and pull of e.g. milk run trolley x x
Bosch* No limit ＞ 0 kg ＞ 0 kg ＞ 0 kg x x x
X = calculation possible * For complete milk run activities

8. ErgoCheck
Ergonomics I – ErgoCheck
Letter from G2, G4, G5, G61 from 26.4.2006 - Extract -
97 Weitergaberecht, bel uns.
Basics
 Requested in the letter from 4G from 26.04.2006
 The layout of manual workplaces must be checked by the work scheduler at least every two years
 Actions
 ErgoCherk-List (11 languages)
 Introduction to the checklist available in German and English
 ErgoCheck has been included in the BPS audit
Checklist Ergonomie in Arbeitssystemen

System/Line: Werk:
Arbeitsplatz: Werkstatt:
1 2 3 5 6
Bearbeiter: Abt: Datum:
Mindestens 70% der relevant Fragen müssen mit “ja“ , maximal 10% der relevant Fragen können mit
7 8 9 10 11 12
“nein” beantw ortet w erden.
1. Körperhaltung und Arbeitshöhe ja tlw nein

.
ErgoCheck
1.1 Kan der Mitarbeiter am Arbeitsplatz eine physiologisch gute Körperhaltung □ □ □
einnehmen?
Kriterien: Kein starkes Beugen des Oberkörpers und Verdrehen des ‘08 ‘ ) ‘10 ‘11 ‘12
Rumfes,
Vermeidung extremer Kopfneigung und –drehung ‘13 ‘14 ‘15 ‘16 ‘17
1.2 * Kann der Mitarbeiter im Sitzen arbeiten? □ □ □
98
Content
 19 questions to evaluate ergonomically manual work
places
 Body posture and working height
 Reach range and field of vision
 Movement area and access dimensions
 Display and manual handling
 Loads and manual handling
 If question 5.1 and 6.1 are answered with “no”

＝＞ K.O. criterion
99 Weitergaberecht, bel uns.
Checklist Ergonomics in Work Systems

e
System/Line: .............................................................................. Plant: ...........................
Workplace: ............................................................................. Workshop: ...........................
Originator: ...............................Department: ........................ Date: ...........................
At least 70% of the relevant questions must be answered “yes”; a maximum of 10% of the questions may be answered “no”.
1. Body Posture and Working Height yes occ.** no

1.1 Can the associate attain a good body posture at the workstation?
Criteria: No strong bending of the upper part of the body and twisting of
the trunk, avoidance of extreme head inclination and head rotation
1.2* Can the associate work while sitting?
1.3* At a Sitting Workplace, does free leg room, thigh room and
a height-adjustable foot rest exist (ref.”Blue Card”)?
1.4**At a Standing Workplace, can the associate also walk
to avoid long-term standing?
1.5 Can the associate work an optimal working height (as per recommendations in
“Blue Card” or DIN33 406)?
* Question applies only if a Sitting Workplace is organizationally, technically
and work-methodically possible.
**Only for stand-walk-production lines: are the stand-walk-criteria folllwed?

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2. Reach Area and Field of Vision yes occ.** no
2.1 Can the associate reach easily to the cyclically used containers, tools, parts or
measurement equipment?
2.2 Are cyclically used positioning points in the center of the working area?
2.3 Does the associate have a clear view of the process area?
2.4 Is there sufficient illumination at the workplace?
2.5 Is galre at the work station avoided?
3. Movement Space and Access

3.1 Does the associate have enough movement space at the workplace?
3.2 Does enough freedom of movement exist for maintenance activities an setup?
3.3 Can magazines, containers or feeder bowls be simply refilled
or changed (without bending and stooping)?
4. Displays and Operating Devices

4.1 Can the control panel (operating devices and display) be reached and observed
easily during working or setup?

e
yes occ.** no
4.2 Is the control panel positioned at optimal operating height?
4.3 Are frequently (>100 time/shift) observed displays and used operating devices:
- not located above head height (max.1500 mm height)?
- located as close as possible to the working location?
4.4 Are all displays and operating devices (used ≦100 times/shift) located at a height
less than 1800 mm?
4.5 Are frequently observed observed displays placed in the center of the field of vision?
5. Weight of Parts and Handling Loads

5.1 Is there adherance to the recommended limit values of forces and efforts
by manual tasks? (calculated with the software IGEL)
6. Hazard assessment
6.1 Is there a hazard assessment available?
**occ.=occasionally
C/MPS3 10.2010

Ergonomics Basics For Workplace Design

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C/MP - Manufacturing Coordination, Production System

Development and Investment

Ergonomics basics for

Ergonomics basics for

Ergonomics basics for workplace design

Adaptation to the human

Physical strain - stress

External influences on human

Physical and mental

What has to be designed ergonomically?

Work table Fixture

Case lifter Work chair

Physiology Organization Environment

Effort Cyclic work Illumination

Aspects of the workplace design

Information Anthropometrics Laws

Operational Elements Working heights Safety

Allgemeine Liefervorschriften für Maschinen, Replaces edition 2008-10-30

In case of doubt apply the German version of this Bosch-Norm.

Property of Robert Bosch GmbH 2 Scope

- Hazard -Hot and cold-related media

- Risk assessment Method to identify hazards and define their characteristics.

Bosch Norm N93 A11

Ergonomics basics for workplace design

Body height and percentile

Body height and percentile in Germany

♂ Body height 158 165 175 185 189 cm

♀ Body height 147 153 162 172 176 cm

Source: DIN 33402, Dec. 2005

Body height and percentile in Europe

Source: Arbeitswissenschaftliche Erkenntnisse Nr. 108.

Body measurements further countries

Poland 1501 1587 1667 1627 1730 1821 18-60 1984

France 1510 1590 1700 1590 1700 1810 1982

Spain 1430 1590 1710 1530 1650 1770 1978

USA 1511 1615 1720 1636 1748 1853 18-65 1973

UK 1478 1608 1737 1580 1709 1839 1973

Pygmies 1360 1410 18-30 1950

China (Yangste Fluss) 1560 1670

China (Si Chuan) 1530 1630

Russia 1508 1595 1680 1614 1723 1832 18-21 1977

Lithuania 1570 1651 1731 1672 1768 1864 18-21 1977

Example of use of the body measurement values

Male Female Male Female

5. 50. 95. 5. 50. 95. 5. 50. 95. 5. 50. 95.

Source: DIN 33402, Dec. 2005

Ergonomics basics for workplace design

In the ideal case, which components should be adapted by the

Energy expenditure according to posture and type of work

Rest 0 NO muscle work 0

Knee 3.0 high 6.0-8.5

Relation between work content and body posture

Assembly work Assembly of small and medium parts ● ●

Use of visual/optical aids Microscope workplaces, visual inspection with binocular ●

Missing free room for legs Fundament under machining ●

Handling of big parts Frequent handling of parts ＞ 300×300×300mm (e.g. packaging) ●

Ranking of body postures

Sitting and Standing

Hydrostatic blood pressure in the legs ■ □

Static holding work, demand on supporting and ■ □

Curbing breathing and digestion □ ■

■ High requirements Medium requirements □ Low requirements

Changing the body posture

- Hazard 　 -Hot and cold-related media