Paper ID: 06
An Ergonomic Evaluation of Work Place in Steel and
Power Industry - A Case Study
Dr. Kottala Sriyogi
Assistant Professor, Department of Industrial and Production Engineering,
Institute of Technology, Guru Ghasidas Vishwavidyalya
Bilaspur, (C.G) India
E-mail: kottalasriyogi@gmail.com
Abstract— A large number of steel and power production
industries are situated in the state of Chhattisgarh where
availability of raw material is plentiful and cheap. This paper
reports the results of an ergonomic study in steel and power
production plant situated in Chhattisgarh. The main objective
of this paper is to evaluate the working conditions of the plant
from an ergonomics perspective and recommended feasible
solutions to management for implementation. The investigation
was done by a questionnaire survey as well as by observations
in the workplace as a single case study. The results indicated
that the plant conditions were stressful, with poor safety, weak
interfacing with work equipment as well as physical workplace
layout design. The results also revealed that noise, vibration,
climate, illumination, and working posture were not an
acceptable limit as ergonomic perspective. However, major
positive research finding was conducive condition in the work
environment resulting low absence rate among employees due
to illness.
Keywords— Steel, power, production, ergonomics, work design,
workplace, evaluation.
I.
INTRODUCTION
According to International Ergonomics Association (IEA):
“Ergonomics (or human factors) is the scientific discipline
concerned with the understanding of interactions among
humans and other elements of a system, and the profession
that applies theory, principles, data and methods to design in
order to optimize human well-being and overall system
performance.”[1]
Ergonomics is the application of scientific principles, methods
drawn from a various disciplines for the development of
engineering systems, the role of human is significant [2].
Automation and advancement of technology lead to
replacement of large amount of human resources in industrial
systems, however, some tasks are being done manually by
human resources [3]. During the manufacturing process of
0
steel temperature of 1600 C pig iron melts and collects at the
bottom of the furnace. The waste gas from the blast furnace,
which is rich in carbon monoxide, is burned in blast furnace
stoves to heat the air blown into the furnace and may be used
as a fuel elsewhere in the steel plant.
The majority of operations in the steel and power industry
exposes workers to a wide range of hazards or work place
Electronic copy available at: http://ssrn.com/abstract=2431575
activities or conditions that could cause accidents which may
lead to death, ill health or diseases.
In order to avoid either catastrophic or non catastrophic
accidents either controllable or uncontrollable factors within
the work place can be achieved by adopting the ergonomic
perspective design of the workplace. Ensuring conducive
physical conditions plays vital role in enhancing the
productivity. In our study, we have observed the shop floor of
steel as well as power production plant where the workers are
exposed to noise, vibration, climate and illumination are not at
permissible limit. However, strict enactment of laws by
government bodies failed to ensure the various issues related
to the safety of employees. This paper comprises of five
sections at first introduction second a structured, relevant
literature review, third methodology used to accomplish the
objectives of the fourth study, results and discussion followed
by a conclusion.
II. LITERATURE REVIEW
Methodology of Literature Review: Both Nationally and
Internationally available Open access referred scholarly
journals and publications related to the topic of this review has
been considered. Key words used in the search were steel,
power, production, ergonomics, work design, workplace, and
evaluation. For this search, the most relevant papers in terms
of technical content were considered. Total thirty seven
research papers were reviewed.
Several forces necessary for work, excessive forces are
injurious. Mechanical properties of skin have its importance
while doing manual work [4], Comprehensive workplace
health promotion programs reduce disability days among blue
collar employees and provide a good return on investment [5].
Procedures and findings of a study of workplace learning
arrangements in a mining and secondary processing plant [6].
Proposed that the level of control approach offers a potentially
rich interpretive framework for the effects of stressors on
performance [7].
Examined the reliability and validity of two
musculoskeletal symptom surveys [8], a critical review of the
applicability of theoretical models of health behavior to
workplace self-protective behavior [9]. The evidence for (or
against) the utility of ergonomic interventions it is mapping
the issues in intervention to prevent musculoskeletal disorders
Paper ID: 06
[10], evaluated the usefulness of different measurement
methods in terms of accuracy and applicability. The
assessment of external exposure measures by subjective
judgments (from experts or self reports from workers),
observational methods (on site or afterwards from video
recordings), and direct measurement methods (at work or
during laboratory simulations) are discussed for each of the
dimensions of exposure level, duration, and frequency [11].
Identified the risk factors facing in an organization among
employees by the continued use of computers and other
equipment in the office environment, and administered an
employee symptom survey, along with a job station analysis
[12]. Examined the relationship of repetitive work and other
physical stressors to prevalence of upper limb discomfort,
tendinitis, and carpal tunnel syndrome [13]. Relevant studies
on few scientific approaches; the first approach is based on the
direct analysis of the real workstations, while the second one
used computerized models to design workstations
ergonomically [14].
Discussed new trends in developing and implementing
methods of workplace analysis [15]. Reported the results of
the project's initial workplace job task screening for
ergonomic risk factors and associated musculoskeletal
disorder reports to define landmark ergonomic risk factors for
the nursery industry [16]. Work-related musculoskeletal
disorders are increasingly asked about the evidentiary base for
mechanical exposure reductions [17]. Work focused on
identification of potential hazards and determined risk
potential of the workplace environment in regards to
ergonomic factors [18].
Observed the key work factors associated with psychological
ill health and sickness absence in staff were long working
hours [19]. Work on physical ergonomic features of work
frequently cited as risk factors for MSDs include rapid work
pace and repetitive motion, forceful exertions, non-neutral
body postures, and vibration [20]. Analyzed important
research dimensions related to different movements, selected
seat design considerations [21]. Studied musculoskeletal
disorders continue to be a major source of disability and lost
work time understanding their causes, and especially those
that are work-related, remains the key to primary prevention
[22].
Strengthen the position of ergonomics and ergonomists; they
discussed the opportunities to link ergonomics explicitly to
company strategies and business goals [23], placing a limit on
the risk associated with a particular work schedule is likely
more effective than setting daily, weekly or monthly work
hour regulations in keeping workplace safety within
acceptable limits [24].
The study presents measurements of airborne concentrations
of respirable crystalline silica in the breathing zone of workers
who were anticipated to encounter coal fly ash. Six plants
were studied; two were fired with lignite coal, and the
remaining four plants used bituminous and sub bituminous
coals [25]. Reports the results of an ergonomic study in an
export garment manufacturing plant in South East Asia to
evaluate the working conditions of the plant from an
Electronic copy available at: http://ssrn.com/abstract=2431575
ergonomics/human factors perspective [26]. Identified two
broad categories for the prevention of workplace violence, pre
incident strategies, post incident strategies [27].
Quantitative analysis of literature relevant to safety issues by
Meta analytics examining the person and situation based
antecedents of safety performance behaviors and safety
outcomes (i.e., accidents and injuries) [28].
Explored the quantitative relationship between exposure to
physical risk factors and upper extremity work-related
musculoskeletal disorder is virtually unknown [29].
A participatory workplace intervention was developed in
which an employee and supervisor identify and prioritize
obstacles and solutions the results of this study indicate a high
feasibility for a broad implementation of a participatory
workplace intervention for employees with distress and lost
time, and their supervisors [30]. Analyzed risk reduction of
ergonomic injury which include the use of ergonomic lift
assisting equipment, the use of carts to transport materials, the
redesign of production equipment to improve ergonomics,
reduce awkward postures, and monitoring of improvements
made to ensure effectiveness of treatment [31].
A case study of the human handles the work according to the
human engineering principles perspective; analyzed the force
on human wrist, knee and ankle in different situations based
on the working posture [32].
Work presented the risk assessments undertaken and potential
control measures identified [33]. Evaluated the inter-rater
reliability of the American Conference of Governmental
Industrial Hygienists (ACGIH) hand activity level (HAL), an
observational ergonomic assessment method used to estimate
physical exposure to repetitive exertions during task
performance [34]. Work on safety for steel industries, while
processing of steel with respect to thermal conditions like
temperature, humidity, air velocity, illumination, noise and
pollution agents in housekeeping [35]. Determined an on-body
personal lift assistive device (PLAD) affected oxygen
consumption during a continuous lifting task and to
investigate if any effect could be explained by differences in
muscle activity or lifting technique [36].
Examined whether vibration reducing gloves can attenuate the
vibration transmitted to the fingers and to enhance the
understanding of the mechanisms of how these gloves work
[37].
Observed the psychological and physiological fatigue
variation in shift workers and the subjective factors affecting
the fatigue of line maintenance crews [38]. Proposed some
preliminary quantitative data describing the hand movement
time for younger and older female adults during machine
paced assembly work. Proposed that age did not have a
significant effect on hand movement time [39]. Work based on
clothing local ventilation measuring device based on the
Lotense Havenith steady state tracer gas method was
developed and an improved experimental method for
understanding local ventilation mechanisms. [40].
Paper ID: 06
Research Objectives: included hearing loss, increases in blood pressure, headache
irritation etc. to the people. Permanently damage nerve of inner
i. To examine and assess the role of physical factors (noise,
ear. It was observed that noise level is more than 90 dB in the
lighting, vibration, and indoor climate) that affect the
central workshop of the plant considered in this study.
working conditions for the workers.
ii. To determine the extent to which the ergonomic factors Table:1 OSHA Standard limit for noise explore
(working posture, repetitive work, lifting, and other Duration DB
ergonomic conditions) impact the efficiency of the workers.
8 hour 90
iii. To determine the conditions in the work environment that
can contribute to absence due to illness (heavy lifting, 4 hour 95
allergy etc.). 1 hr 105

25 min 115
III. METHODOLOGY
The case study is the most flexible of all research designs,
allowing the researcher to retain the holistic characteristics of
real-life events while investigating empirical events. In Table : 2 Illumination Standard
general, a case study is an empirical inquiry which Category Range of Illumination Type of activity
(LX)
investigates a contemporary phenomenon within its real-life A. 20-30-50 Public area with dark
context: when the boundaries between phenomenon and surrounding.
context are not clearly evident and in which multiple sources B. 50-75-100 Simple orientation for
of evidence are used. [40]. According to the case study does short term visit
C. 100-150-200 Working space where
not claim any specific data collection methods, but “focuses visual task of high
on holistic description and explanation” [41]. Within this contrast or small size.
focus, the case study can be further described as D. 200-300-500 Performance of visual
task of high contrast or
particularistic, heuristic, or descriptive. Type of case study large size reading
discussed in this paper is exploratory and descriptive. A printing material, ordinar
questionnaire has been adopted from previous studies [42]. y inspection.
E. 500-750-1000 Performance of visual
We have used single case using survey instrument. The data task of medium high
has been anonymously collected from the workers during their contrast or small size.
duty hours at various shops and places on the premises of steel F. 1000-1500-2000 Performance of visual
task of low contrast or
and power plant located in Chhatisgarh. The data has been very small size.
collected from various departments of the plant comprising: G. 2000-3000-5000 Performance of visual
Central Workshop, Water Treatment Plant, and Civil task of high contrast or
very small size over a
Department. The aim of data collection for the analysis of the prolong period.
workplace, ergonomic conditions prevailing. H. 5000-7000-10000 Performance of special
A questionnaire comprises of fifteen relevant questions. The visual task of extremely
low contrast or
questionnaire covers all aspects of ergonomics suitability and small size
other physical condition concerning issues of work place. The
sample size was thirty four.
About the company: Coal-based sponge iron plant a leader in It has been observed in some parts of plant i.e central work
manufacturing coal-based sponge iron in India. Leads the shop and civil department not following the illumination
Indian market in this sector and has the world’s largest coal- standards especially category A, D is missing in central work
based sponge iron plant, with a capacity of producing 1.32 shop. Category F,G missing in Civil department. We offered
MTPA DRI. It is the only sponge iron manufacturer in the our recommendations as per existing illumination standard of
country with captive raw material resources and power steel industry i.e table 2.
generation. It has modern rail and a universal beam mill. The
mill has a wide range of products ranging from long rails up to
121 meters to medium and large size parallel flange beams
and columns. The product mix includes: Track Rails, Crane
Rails, Parallel Flange Beams and Columns and Channels.

IV. RESULTS AND DISCUSSION

Any unwanted sound can be defined as noise. From table my
interpretation is if the decibel level of noise is above the
acceptable value (85 dB). Effect on man It causes noise

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Paper ID: 06
the workers. A few problem areas identified are related with
Practices observed at workplace for ergonomic the noise from the equipments, workplace environment like
evaluation: flooring, covering, fire extinguishers etc, vibrations, equipment
lighting, and indoor climatic conditions.
Table:3 Few respondents faced problems with the ergonomics
Problems with Physical Conditions concerned with Yes (%) No conditions caused by lifting, repetitive work and working
(%) posture. Some of the problems we observed at the organization
(i) Workplace environment 43 57 with respect to Physical conditions Ergonomic aspects Safety
(ii) Noise 86 14 (conditions causing determined risk of accidents).
The factors mentioned above do not hamper the productivity of
(iii) Vibration 71 29
the company but it is evident manner but they definitely
(iv) Lighting 43 57 hamper the efficiency of the workers in a long run.
(v)Climate 64 36
The workers could be able to give their optimum performance
at workplace if the working conditions are favorable and when
(vi)Ergonomics 26 74 these conditions do not pose as a hindrance. Thus, putting an
(vii) Conditions at workplace which can cause 79 21 effort towards improving the existing conditions at workplace
determined risk of accidents will ensure high work output from the workers. This helps in a
(viii) Conditions in the work environment that 94 6 smooth functioning of the company as well as employees’
contribute to absence due to illness
safety are an integral and the most important issue of the
company.
From table: 3 interpretations of problems observed through our
survey one of the positive finding of the workplace. Six percent
of respondents say that there are such conditions in the work Safety: Safety (Conditions causing
environment that contribute to absence due to illness. determined risk of accidents)

Table : 4
(i) Factors that cause work place environment problems
In Percentage
Physical Conditions:
Work place layout 57

Workplace Environment
Space 43
Noise
Ergonomic Aspects
(ii) Factors that cause problems with physical conditions related to noise
Vibrations

Lighting
Equipment 92
Indoor Climate
Ventilation 08
Figure: 1 A framework for ergonomic workplace evaluation
(iii) Factors that cause problems with physical conditions concerned
with lighting
Letting in day light 16 Safety (conditions causing determined risk of accidents):
Proper safety measures must be taken into consideration by
Equipment Lighting 67
placing fire extinguishers at equal intervals, first aid kits etc.
Room Lighting 17 Physical conditions:
(iv) Factors that cause problems with Indoor Climate Workplace Environment: The problems with workplace
environment related to workplace layout solved by redesigning
Heat 67 the workplace using structured and scientific approach.
Smell 22 Noise: Since noise from equipments in operation is
unavoidable, ear plugs must be provided to the workers and its
Cleaning 11
usage is mandatory for every worker prone to high noise levels.
(v) Factors that cause problems related to Ergonomics Vibrations: Vibrations should be minimized at the source or by
Working Posture 33
reducing the force transmitted, by converting vibration energy
into thermal energy by using mechanical or hydraulic dampers
Repetitive Work 22 and by altering body position or body support.
Lifting 45 Lighting: Problems with equipment lighting can be minimized
by letting in day light. Contrast, quality and amount of
illumination should be improved by incorporating the concept
The survey was majorly concerned with the analysis of the of sustainable green design, HVAC of plant.
physical conditions present at the workplace considered for this Indoor Climate: Majority of the respondents uncomfortable
study. Overall the physical conditions provided to the workers with the indoor climate caused by heat. Providing good
at the organization considered in this study were favorable for ventilation, installation of industrial coolers, however for the

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Paper ID: 06
workers who work at extreme heat zone air conditioned rest
rooms with periodic breaks considering fatigue allowance of
the job.
Ergonomic aspects
Working Posture: To ensure appropriate working posture,
maximum comfort to the operator. The work place must be
designed considering, height of the chair and other dimensions
should be designed using standard anthropometric data being
practiced in steel and power industry.
Conclusion:
As human intellectual capital is one of the main pillar of any
organization. They are many reasons for sustainable and
effective functioning of the company. Productivity of a
company depends upon employee’s performance. Hence,
providing a favorable working environment to the workers
plays a crucial role in determining company’s growth. As
ergonomics is the design of a workplace to ensure there is a
good fit between the workers and what they interact with in
their environment. Ergonomics is important because it makes
workers be in better health, sound mental attention be more
effective as they have to work in pleasant environments.
From this study we conclude that better the workplace
conditions, better the performance of the workers and hence
higher the productivity, labour productivity of the company.
Apart from direct physiological effects, better working
conditions induce psychological effects on the workers too, as
these factors are motivational tools to enhance the workers
performance to optimum level. Provision of ergonomic
working conditions act as a driving force in increasing the
workers zeal to work. Hence, designing and improving the
existing working conditions will help organization for surving
in the business environment for sustainable growth.
Acknowledgment
Due acknowledgements to Dr.Mukesh Kr.Singh, Prof & Head,
Dept of IPE, for extending his support in completing this
research work.
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