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Ergonomic Evaluation Tools RULA and REBA Analysis: Case study.

Conference Paper · October 2014

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Ganesh S. Jadhav Suresh M. Sawant

AGTIS Dr.Daulatrao Aher College Of Engg.Karad Rajarambapu Institute Of Technology, Rajaramnagar, Sakharale, Islampur
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 Ergonomic Evaluation Tools RULA and REBA
Analysis: Case study.
Mr.Ganesh S.Jadhav [1], Assistant professor
Department Of Mechanical Engineering
Dr.Daulatrao Aher College Of Engineering Karad
Dist-Satara, India
E mail-gsjadhav@yahoo.co.in
Dr.S.M.Sawant [3], Professor
Department of Mechanical Engineering
Rajarambapu Institute of Technology, Rajaramnagar
Islampur Dist-Sangli
Abstract— REBA and RULA is one of the most popular
ergonomic assessment tools in an industry. A method for
ergonomic evaluation of complex manual work was developed,
based on working operator assessment of video recordings and
photographs. Based on the reviewed literature, postural activity
guidelines are proposed summarizing analysis of workers activity
for discomfort has been reported. Demographic characteristics of
industrially developing countries and some comparisons with
industrially advanced countries, particularly those aspects
relevant to ergonomics, are presented with the help of case
studies. This tool identifies injury risk and also set the priorities.
Keywords—REBA,RULA
I. INTRODUCTION
This paper concerns with study of ergonomics and fatigue
during manual process in ABC company in India. The manual
process is recorded with high definition video camera. This
video is analyzed and discussions are made with workers
regarding health issues during the process. Two techniques
Rapid Entire Body Assessment (REBA) and Rapid Upper
Limb Assessment (RULA) are then used to evaluate postural
loading on whole body. Similar manual process is assessed
from other developed countries whose ergonomic conditions
are more improved for the same task. The results are then
compared and some conclusions are made.
A. Ergonomics
Ergonomics deals with physical and psychological
behavior of worker during process.Operator data is collected
from ergonomic study which assesses human capabilities
during their work related task.
Mr.Gurunath V Shinde[2], Assistant Professor
Department Of Mechanical Engineering
Dr.Daulatrao Aher College Of Engineering Karad
Dist-Satara, India
E mail-gurunathshinde@yahoo.com
Mr.Vahid.M.Jamadar [4], Assistant Professor
Department Of Mechanical Engineering
Dr.Daulatrao Aher College Of Engineering Karad
Dist-Satara, India
B. Fatigue
Fatigue is caused by stresses developed from some
complex task during process.This causes effects on
cardiovascular system, physiological system and
psychological system.
II. METHODOLOGY
This process requires heavy material handling which
may lead to musculoskeletal injuries. This process is
recorded, observed, analyzed and documented. Two
established tools viz Rapid Entire Body Assessment (REBA)
and Rapid Upper Limb Assessment (RULA) are used for
ergonomic assessment of manual task in India and one of the
developed countries with the help of case study.
A. Process
Different movements lifting, shifting and material
mounting are asked to perform by worker for manual process
which is recorded by high definition video camera for further
analysis. Task time and repetition of task were recorded from
video. Neck, trunck, leg, arm angle were first examined.
Scores are calculated from REBA and RULA survey.
Depending upon final score REBA and RULA
recommendations are made. The analysis is made for spool
lifting, shifting and mounting activity in India plant and other
developed country plant.
B. Score charts
RULA:
RULA is method developed for ergonomic analysis of
workstations where upper limb activities are reported to be
hazardous. In RULA close observations are made with joint
angles, task time and forcing. First, lower arm, upper arm,
and wrist postures are examined Then a posture score is
determined from table A using the numerical values of
the observations. Next a muscle use score and force
score are added to the value determined by table A. Next
the trunk, neck, and leg observations are made. The
postures are then given a numerical value in relation to
how far they deviate from the neutral position. A posture
score is determined from table B using the numerical
values of the previous observations. Next a muscle use
score and force score are added to the value determined
by table B. Once the values from section A and B have
Table.1. (c)
been calculated, they are used to find a final score from
Table C. The RULA then lists a range of values that
have recommendations assigned to them.
Table.1.(a) to (d) shows RULA analysis of arm, wrist, neck,
trunck and leg analysis in manual process in ABC company in
India and other developed country. The analysis is done for
spool lifting, shifting and mounting activity

Table.1. (d)
Fig.1. (a), (b), (c) and (d) RULA analysis of manual process in
India and other country.
REBA:
REBA is method developed for ergonomic analysis of
Table.1.(a) workstations where entire body activities are reported to be
hazardous. To perform a REBA assessment, observations
are made of the limbs and body postures most frequent
used, paying close attention to extreme joint angles,
duration, forces. First, observations are made of the
trunk, neck and legs. The postures are then given a
numerical value in relation to how far they deviate from
the neutral position. Then a posture score is determined
from table A using the numerical values of the previous
observations. Next a muscle use score and force score
are added to the value determined by table A. Then, the
lower arm, upper arm and wrist postures are examined.
Table.1. (b) The postures are then given a numerical value in relation
to how far they deviate from the neutral position. Then a
posture score is determined from table B using the
numerical values of the previous observations. Next a
muscle use score and force score are added to the value
determined by table B. Once the values from section A
and B have been calculated, they are used to find a score
from Table C. The table C score is combined with an
activity score to produce a final score. The REBA then
lists a range of values that have recommendations
assigned to them. Table.2.(a) to (d) shows REBA analysis of
arm, wrist, neck, trunck and leg analysis in manual process in
ABC company in India and other developed country. The
analysis is done for spool lifting, shifting and mounting
activity
III. RESULTS
A. RULA:
Fig.3.shows comparisons of spool lifting, spool shifting
and spool mounting RULA score for manual process in India
(Before) and other developed country (After).In developed
country spool lifting, spool shifting and spool mounting
process is done by overhead jib crane with hook provided by
vacuum to attach spool, hence REBA and RULA results
shows reduced level of risks.

Table.2. (a)

Table.2. (b) Fig.3 Comparison of RULA survey results for manual process
in India and other country
B. REBA
Fig.4.shows comparisons of spool lifting; shifting and
mounting REBA score for manual process in India (Before)
and other developed country (After). In developed country
lifting, shifting and mounting process is done by overhead jig
with hook to attach spool, hence REBA and RULA results
shows reduced level of risks.

Table.2. (c)

Fig.2. (d)
Table.2. (a), (b),(c) and (d) REBA analysis of manual process
in India and other country. Fig.4 Comparison of REBA survey results for manual process
in India and other country
 IV. CONCLUSIONS
Ergonomic assessment of manual process in ABC
company in India and other developed country is done by [1]
capturing video of process. REBA and RULA techniques are
used for assessment of ergonomic risks during process. It was
[2]
found that the current process has a high risk of health issues
resulting from heavy loads/ excessive forces and awkward [3]
postures in India. Hence REBA and RULA score shows
unacceptable level of risks. Similar process is assessed
[4]
in other developed country. REBA and RULA score for
this process in other developed country shows reduced
and acceptable risks level. Following score system [5]
should be taken into consideration regarding REBA and
RULA after analysis of videos of operator’s activity.
[6]
[7]
Acknowledgment
We are especially thankful to Shrinivas Patil,Manager
Plant-Service and IEHS,Vishay Components India Pvt
Ltd,Loni Kalbhor,Pune.We are also thankful to all
managers,engineers and workers of Vishay Components India
Pvt Ltd,Loni Kalbhor,Pune who are involved during carrying
out this work.
References
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Hignett and McAtamney,”Rapid Entire Body Assessment (REBA)” ,
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McAtamney and Corlett, “RULA: a survey method for the investigation
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