REPORT ON

IAESTE INTERNSHIP
AT
DEPARTMENT OF ENGINEERING MANAGEMENT
POZNAN UNIVERSITY OF TECHNOLOGY, POLAND
IN THE GUIDANCE OF
DR. GREGORZ DAHLKE

SUBMITTED BY
ASHISH KONA
MIT MANIPAL
REG NO 130905266

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Table of Contents

Sr No. Contents Page No.

Certificate 3
Acknowledgement 4
1 Preface 5
2 Introduction 6
2.1 Ergonomics in Industries & Industrial Work Processes 6
2.2 Ergonomics and Mechanical Engineering 6
3 Software Exposure 7
3.1 ErgoEASER 7
3.2 3DSSPP 12
3.3 CASE STUDY : Ergonomics in Industrial Process 18

4 REBA Worksheet 21

5 Anthropometric Data Measurement 22

5.1 Torque Tester 22
5.2 Force Gauge 25
5.3 Hand Dynamometer 26
5.4 Audiometer 28
5.5 Pressure Sensitive Foot Analysis 30
5.6 Body Composition Analysis 31
6 Psychophysical Data Measurement Techniques 32
6.1 Wirometer 32
6.2 Stereometer 33
6.3 Vibration Testing Meter 34
6.4 MPR Meter Reaction Time 35
7 Conclusion 36

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3
 Acknowledgement

I would like to thank Mr. Grzegorz Dahlke and Ms. Milena Drzwiecka for allowing me to train in the
discipline of Ergonomics at the Poznan University of Technology. I am grateful to them for guiding and
imparting knowledge to me throughout my internship. They have been instrumental in developing a
strong base for me in Ergonomics. Also, I would like to thank Mr. Martin Butlewski for providing us an
opportunity to analyze an industrial process. Moreover, I would like to pay sincere thanks to all the staff
of the department for their assistance. I sincerely believe this internship will help me in all my
engineering endeavors.

July 24th 2016 Ashish Kona

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 Preface

Indian industries are labor intensive due to the population density. Since complete automization of such
industries is not feasible keeping in mind the job opportunities they generate, manual labor is preferred.

Human factors and ergonomics (HF&E), also known as comfort design, functional design, and
systems, is the practice of designing products, systems, or processes to take proper account of the
interaction between them and the people who use them.

The field has seen contributions from numerous disciplines, such

as psychology, engineering, biomechanics, industrial design, physiology, and anthropometry. In essence,
it is the study of designing equipment, devices and processes that fit the human body and
its cognitive abilities. The two terms "human factors" and "ergonomics" are essentially synonymous.

And for such a labor intensive country, Ergonomics can prove as a growing field and has potential to
ease work processes, come up with better design and improve human interactions with the work
environment.

It is an integral part of engineering development that we focus on the human interaction as well as the
desire effect. Training in ergonomics aims at providing the technical knowledge and skills required for
industrial operations keeping human comfort in mind.

With the purpose of getting exposure to the real working environment and a hands on experience of
working equipment used in developed countries in the field of ergonomics, I underwent a 6 week
internship and training at Pozan University of Technology, Poznan, Poland.

I hope to be able to share my ideas to improve the quality of life in my own country.

The following pages contain a report on the practical training undergoing by me in the Department of
Engineering and Management, Poznan University of Technology, Poznan, Poland.

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 Chapter 2 : Introduction

2.1 Ergonomics in Industries and Industrial Work Processes

Certain ergonomics norms and standards are required to be followed in processes done in industries so
as to prevent injuries and minimize occupational hazards. To maintain work safety conditions and retard
physical musclo-skeletal problems associated with work processes such as stacking of racks, de-stacking
etc, ergonomics is required.

2.2 Ergonomics and Mechanical Engineering

Ergonomics paired with the concepts of Mechanical engineering goes hand in hand. A mechanical
engineer equipped with the concepts of ergonomics is a definite necessity in today’s time. Mechanical
industries tend to deal with industrial processes which are human intensive. And the designing of
industrial equipment such as lathes, milling machines, dynamic balancing machines can be carried out
with ergonomic criteria.

Many industries have successfully implemented ergonomic solutions in their facilities as a way to
address their workers' MSD injury risks. These interventions have included modifying existing
equipment, making changes in work practices and purchasing new tools or other devices to assist in the
production process. Making these changes has reduced physical demands, eliminated unnecessary
movements, lowered injury rates and their associated workers' compensation costs, and reduced
employee turnover.

Fig. No. 1.1

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 Chapter 3 : Software Exposure

3.1 ErgoEaser

Ergonomics Education, Awareness, System Evaluation and Recording, ErgoEASER, is a

software package that has been developed to aid in identifying, evaluating, and preventing work-
related musculoskeletal disorders. Evaluating video-display terminal (VDT) workstations and
lifting task design, ErgoEASER offers suggestions on how to address ergonomic hazards and
reduce worker disabilities.

From the POV of a mechanical engineer, it will provide us an opportunity to design accordingly.

Fig. 3.1 shows a schematic layout for a workstation following ergonomic standards.

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 Fig. No. 3.1

The engineering drawing in Fig 3.1 shows the conventional workstation and also a proposed workstation
according to ergonomic standards.

The significant changes that can be seen are:

The change in shape of the table and the reduction in table size.
The accessibility of the things on the table have also increased.

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The following figures show the use of the software ErgoEASER to design the workstation. The red
crosses in figure 3.2 are indication of wrong ergonomic condition.

This shows existing conditons and as can be seen by the red crosses that changes are to be done.

The new conditions can be simulated using the various paramaters as seen in the software window.

Fig. No. 3.2

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 Fig. No. 3.3
Fig. No. 3.3 shows different parameters with respect to the human and the chair as compared to
the previous figure which showed the parameters with respect to the chair and the environment.

Fig. No. 3.4 indicates the standard parameters for a European Male.

Fig. No. 3.4

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 Fig. No. 3.5

The software then suggests changes according to the ergonomics norm, The software helps in making workstation
ergonomic in nature.

And hence can be used to provide a suitable design to chairs, tables and the computer screen.

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3.2 3D Static Strength Prediction Program

3.2.1 Introduction

3D SSPP software predicts static strength requirements for tasks such as lifts, presses, pushes, and pulls.
The program provides an approximate job simulation that includes posture data, force parameters and
male/ female anthropometry. Output includes the percentage of men and women who have the strength
to perform the described job, spinal compression forces, and data comparisons to NIOSH guidelines.
The user can analyze torso twists and bends and make complex hand force entries. Analysis is aided by
an automatic posture generation feature and three dimensional human graphic illustrations.

3D SSPP can be used as an aid in the evaluation of the physical demands of a prescribed job.
Furthermore, the 3D SSPP can aid the analyst in evaluating proposed workplace designs and redesigns
prior to the actual construction or reconstruction of the workplace or task. The program is applicable to
worker motions in three dimensional space. 3D SSPP is most useful in the analysis of the “slow”
movements used in heavy materials handling tasks since the biomechanical computations assume that
the effects of acceleration and momentum are negligible. Such tasks can be evaluated best by breaking
the activity down into a sequence of static postures and analyzing each individual posture. The 3D SSPP
assumes the analyst understands the application of the NIOSH design and upper limit criteria for
strength and disc compression forces (refer to Appendix III for details). The program should not be used
as the sole determinant of worker strength performance or job designs based on that performance. Other
criteria and professional judgement are required to properly design a safe and productive job.

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3.2.2 Simulation performed:

A video was provided to us, of a worker lifting a heavy tyre and changing the position of the tyre from
one rack to another.

Aim: To minimize ergonomic risk associated with the process using 3DSSPP and to analyse the work
process.

Calculations involved: Torque and Force calculations in the lifting procedure.

Process:

1) A video is provide and screenshots are taken to act as reference.

2) A screenshot is taken twice every second for relevant processes.
3) These screenshots then act as a background in 3DSSPP.
4) The humanoid model is arranged according to the background.
5) The strength parameters are noted.
6) The center of balance is noted.
7) Any stress inducing position is changed.

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Fig 3.6. Worker lifting the tyre from lower rack

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The force acting in downward direction is gravitational force. T
The reaction on the wrist can be calculated using the equation :

4.3 cm -> 57cm

1cm -> 57/4.3*100 = 0.132m

Therefore, x=2.2*10*9.81*0.132 / 1.8*0.132 = 119.9 N

Which is the reaction force required for the process.

This force is entered in the 3DSSPP as load. It is divided among the two hands equally, and can
be used for further simulation.
And for every frame in the simulation, load needs to be calculated with the changing force
vector.
The force variation causes stress which can be seen from figure below.
The red region is indicative of dangerous stress. The process should be changed to eliminate this
procedure. Green is the preferred stress
Yellow is moderate stress.

Fig 3.7

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Fig. No. 3.8

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Similarly,
1cm -> 12.39
Therefore, x=10*9.81*0.309 / 0.3593 = 84.568
Similarly, reaction forces can be calculated for all positions.

The following figures can be manually used to simulate the work procedure that is taking place.

Fig. No. 3.9 shows, top view, front view and side view (from L->R)

Fig 3.7 shows the analysis results for a particular position of the worker in terms of static
strength. The variations can be noted by varying the model in the above window of the program.

Another way of aligning the model is described using a manual window as shown in Fig 3.10
below.

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 Fig. No. 3.10

3.3. CASE STUDY : Ergonomics in Industrial Process (Tyre stacking and destacking)

An industrial process of stacking and destacking of tyres was video recorded.

Various key positions of most significant stress were captured and screenshots were taken. The
screenshots were then fed into 3DSSPP for analysis.

The following set of screen shots of 3DSSPP depict the process of unloading of a tyre from a rack in a
tyre industry.

The analysis can be seen from the result graph. A total of 80 screenshots were taken and the report
made. It wasn’t feasible to present all the 80 in the report.

But can be provided upon request.

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Fig. No. 3.11

Fig. No. 3.12

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 Fig. No. 3.13

The analysis was made and it was concluded that the process was ergonomically acceptable.

Following the analysis, the REBA Process sheet was filled out and the process was scored.

The above software can be used to assess angles and can also be used to fill ergonomic assessment
worksheets which give a point based score on the basis of comfort levels. Rapid Entire Body assessment
(REBA) is one such worksheet we were exposed to.

Fig.No. 3.14 shows a REBA worksheet.

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 Chapter 4. REBA Worksheet

The Rapid Entire Body Assessment worksheet (REBA) was designed for easy use without need for
an advanced degree in ergonomics or expensive equipment. You only need the worksheet and a pen..
Using the REBA worksheet, the evaluator will assign a score for each of the following body regions:
wrists, forearms, elbows, shoulders, neck, trunk, back, legs and knees. After the data for each region is
collected and scored, tables on the form are then used to compile the risk factor variables, generating a
single score that represents the level of MSD risk:

Fig. No. 3.14

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 Chapter 5. Anthropometric Data Measurement

5.1 Torque Tester

The open and lock forces of bottle caps are important online and offline production parameters. They
can influence the transportation and consumption of products

Basic Applications

BottlePackage
Open and lock force test of the bottle caps for bottled packages for food, pharmaceuticals, e.g.
beverage or tablet bottles

FlexibleTubePackage
Open and lock force test of flexible tube packages for food, pharmaceuticals and cosmetics, e.g. eye-
drop, hand cream and shoe polish, etc.

Screws
Open and lock force test of the screws

Vacuum Flask
Open and lock force test of the caps of vacuum flasks and vacuum cups.

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 Fig. No. 5.1.1

LABEL

1. Test tamper-evident closures; capture both 'slip torque' and subsequent 'bridge torque' with ease.
2. Versatile mounting table, adjustable to accommodate a variety of forms. Integrated drip tray
captures any sample spillage for ease of cleaning.
3. Clear, intuitive controls; dual-purpose membrane keypad allows quick access to common
functions & navigation of the advanced options menu. Features lockable units & 'max display'
mode.
4. LED and audible alarms; establish pass/fail parameters for torque results, and set alarm
notification for instant failure identification. Store 5 separate settings, with easy selection by
operators.
5. Mains input with water resistant cover. Power Tornado directly from mains or internal
rechargeable battery.

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6. Rugged, lightweight & water resistant design (Rated to IP 54); ideal for use on the factory floor.
Nonpainted polypropylene case suitable for use within pharmaceutical laboratories.
7. Easy export of results to a PC, printer or datalogging device via integrated RS232 output socket.
8. On-board memory; store up to 500 results internally.
9. Moulded carry handle; for easy portability.

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5.2 Force Gauge Push / Pull Strength

Manual Material Handling (MMH) tasks are physical work activities that involve exertion of
considerable force because a particular load is heavy or the cumulative loads during a workday
are heavy. Examples of MMH tasks include lifting or lowering, carrying, and pushing or pulling.
This paper focuses specifically on pushing and pulling activities while using a cart or equipment
with wheels or casters. Researchers have identified a number of key factors that must be
considered when designing manual pushing and pulling tasks.. It is the horizontal push force that
matters most, and with the right caster selection and job design, thousands of pounds can be
moved safely and efficiently. Pushing is preferable to pulling for several reasons. You may, from
your own experience, recall that your feet are often “run over” by the equipment when pulling. If
a person pulls while facing in the direction of travel, the arm is stretched behind the body,
placing the shoulder and back in a mechanically awkward posture, increasing the likelihood of
painful, debilitating, and costly injury. Alternatively, pulling while walking backwards is a recipe
for an accident, because the person is unable to view the path of travel. Further, research
demonstrates that people can usually exert higher push forces than pull forces. In some
situations, pulling may be the only viable means of movement, but such situations should be
avoided wherever possible, and minimized when pulling is necessary.

Fig. No. 5.2.1

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 5.3 Hand Dynamometer

Our strain-gauge based isometric Hand Dynamometer can be used to measure grip strength,
pinch strength, and to perform muscle fatigue studies. Use the hand dynamometer with other
sensors (e.g., EKG Sensor) to study muscular

Fig. No. 5.3.1

The following is a list of activities and experiments that can be performed using this sensor.

 Determine if grip and pinch strength are a function of age.

 Compare hand grip strength with pinch strength. Devise and carry out a study to explore if there is a
correlation between them.

 Measure muscle fatigue by exerting maximum grip strength and sustained grasp for as long as possible.
Determine if muscle fatiguing time is similar for all participants and if there is variation between age
groupings and gender. Predict the results of repeated trials for each member of the group.

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 Measure the effect of squeezing a tennis ball repeatedly on grip strength. Squeeze the ball tightly each
evening fifty times for a month. At the beginning of the month, measure and record your basal grip
strength; at the end of the month, record your hand grip strength and analyze how these values compare.

 Determine if there is a correlation between hand size and grip strength. Consider factors such as wrist
and forearm circumference in relation to grip strength and which muscle complexes are involved in
grip strength and pinch strength.

 Measure hand grip strength for dominant and non-dominant hands by gripping the dynamometer in a
neutral non-supportive posture with the sensor in your non-dominant hand. Initiate data collection
while holding the sensor with a neutral grip with eyes closed. Explore what accounts for the similarities
and differences.

Initiate data collection while holding the sensor with a neutral grip with eyes closed. Explore what
accounts for the similarities and differences.

Fig. No. 9.3.2

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 5.4 Audiometer
An audiometry test is performed to determine how well you can hear. This may be done as part of a
routine screening or in response to a noticeable loss of hearing.

The common causes of hearing loss include:

 birth defects
 chronic ear infections
 inherited conditions, such as otosclerosis, which occurs when an abnormal growth of bone
prevents structures within the ear from functioning properly
 an injury to the ear
 inner ear diseases, such as Ménière’s disease or an autoimmune disease that affect the inner
ear
 regular exposure to loud noises
 a ruptured eardrum

Damage to the ear or exposure to loud sounds for a long period can cause hearing loss. Sounds louder
than 85 dB, such as you hear at a rock concert, can cause hearing loss after only a few hours. It’s good to
use hearing protection, such as foam earplugs, if you’re exposed to loud music or industrial noise on a
regular basis.

Sensorineural hearing loss occurs when hair cells in the cochlea aren’t working properly. The cochlea is
the part of the ear that translates sound vibrations into nerve impulses to be sent to the brain.
Sensorineural hearing loss can also occur due to damage to the nerve that carries sound information to
the brain or damage to part of the brain that processes this information. This type of hearing loss is
usually permanent. It can be mild, moderate, or severe.

There are a few tests involved in audiometry. A pure tone test measures the quietest sound you can hear
at different pitches. It involves using an audiometer, which is a machine that plays sounds via
headphones. Your audiologist or an assistant will play a variety of sounds, such as tones and speech, at
different intervals into one ear at a time, to determine your range of hearing. The audiologist will give
you instructions for each sound. Most likely, they’ll ask you to raise your hand when a sound becomes
audible.

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 Fig. No. 5.4.1

Fig. No. 5.4.2

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 5.5 Pressure sensitive foot analysis

Foot plantar pressure is the pressure field that acts between the foot and the support surface during
everyday locomotor activities. Information derived from such pressure measures is important in gait and
posture research for diagnosing lower limb problems, footwear design, sport biomechanics, injury
prevention and other applications.

Fig. No. 5.5.1

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The development of miniature, lightweight, and energy efficient circuit solutions for healthcare sensor
applications is an increasingly important research focus given the rapid technological advances in
healthcare monitoring equipment, microfabrication processes and wireless communication. One area
that has attracted considerable attention by researchers in biomedical and sport related applications is the
analysis of foot plantar pressure distributions to reveal the interface pressure between the foot plantar
surface and the shoe sole. Typical applications are footwear design, sports performance analysis and
injury prevention, improvement in balance control, and diagnosing disease. More recently innovative
applications have also been made to human identification, biometric, monitoring posture allocation and
rehabilitation support systems.

5.6 Body Composition Analyser

Weight alone is not a clear indicator of good health because it does not distinguish between pounds that
come from body fat and those that come from lean body mass or muscle. Carrying too much fat is a

condition called obesity, and puts a person at risk for many serious medical conditions including heart
disease, diabetes and even certain forms of cancer. In fact, obesity

Fig. No.5.6.1

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 Obesity contributes to at least half the chronic diseases in western society. Overweight means an
excess of total body weight based on population averages for heights and body frame sizes.
Athletes and very muscular people may be overweight, but that does not mean they are over fat.
Obesity means an excess of body fat regardless of weight.

Chapter 6. Psychophysical Data Measurement

6.1 Wirometer
Stationary device for measuring the differences in speed of the spinning discs. For use in the
diagnosis of psychological testing of drivers. Also useful in the diagnosis of resistance distractors.
The results presented in the form of figures and graphs. Full control of all test parameters including
the ability to change the direction of rotation and the speed of acceleration. To eliminate
measurement error - in the construction of the device, the high-precision motors and system test
strategic elements of the device.

Fig.No. 6.1.1

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 6.2 Stereometer

Modern diagnostic device spatial diversity (stereoscopic), and visual acuity. The current version has
been equipped with a system controlling the research process, including automatic calibration, adjust the
speed of the measuring rods, setting presentation. In order to increase the precision of settings, used
automatic speed switch. Full range of starting positions measuring rods allows multiple measurement of
near vision and gave automatically. The course of study including the current position of the rods is
visualized on the monitor control device.

Fig. No. 6.2.1

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6.3 Vibration Testing Meter
Application:
Meter vibration perception is used for non-invasive testing vibration perception thresholds
operating fingers of man. Research using can be used for monitoring vibration sensory disorders
in the period of employment the employee, ranging from preliminary studies, through periodic
up to the final tests. The results of these studies can be used in the case law of occupational
diseases associated with damage to the sense of touch sensation. You can also diagnose the early
stages of peripheral neuropathies, including carpal tunnel syndrome.

Fig. No. 10.3.1

Description
Meter manufactures sinusoidal vibration acting on the finger of the test subject through a probe
protruding from the housing. The frequencies of vibration are in the range from 250 to 500 Hz.
This allows the study Mechanoreceptor FAII. The frequencies of 250, 400 and 500 Hz allow
diagnosis in accordance with the current local regulations. During the test, the patient holds his
hand on the device by touching the probe vibrating pad of the test finger. The patient keeps the
pressure of the finger probe with a force of 1.2 N. The test is performed by ascending. The level
of vibration increases, and the patient indicates the moment when the sensation of vibration. It is
possible to perform a single test or auto repeat to averaging the level of feeling vibrations.

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6.4 MPR Meter Reaction Time

The test meets the requirements of standardization, objectivity, standardization, reliability and validity,
it has proven diagnostic accuracy in clinical psychological drivers. Apparatus for the study of
psychological and psycho. Research psychomotor skills. The test is accompanied by a manual.
Modern meter response time - apparatus designed to measure speed, adequacy and uniformity of
response to stimuli of light and sound. Used in areas such as: - Research drivers (psychology
transport) - studies of other occupational groups (psychology work) - Research Presentation of
results: - accurate to 2 decimal places and automatic calculation: - average - minimum time and
maximum - span , - the number and type of erroneous reaction: no reaction, the reaction to the wrong
stimulus, the reaction of the wrong button, the reaction premature. Advantages: the meter is equipped
with a modern interface that gives a choice of 5 programs of the study.

Fig.No. 10.4.1

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 Chapter 7. Conclusion

Ergonomics remains an unexplored field in India.It is a branch which inculcates elements of

Biology, Neuro-sciences, Physics and Mechanical Engineering undergoing training for a period
of 6 weeks under Dr. Gregorsz Dahlke at the Department of Engineering Management, Poznan
University of Technology has given me hands on experience and knowledge in this field. I have
gained knowledge in various methods of measurement of scientific data using different devices
which can be analysed to gain insight into ergonomic factors affecting day to day human life.
Ergonomics remains an unexplored field in India. It is a branch which inculcates elements of
Biology, Neuro-sciences, Physics and Mechanical

36