INDUSTRIAL ENGINEERING

AND ERGONOMICS

ASSIGNMENT

By
Shreyas
Akarsha
Table of Contents
1. Introduction..................................................................................................................................6
1.1 Ergonomics............................................................................................................................6
1.2 Ergonomics Assessment........................................................................................................6
1.3 Need of ergonomic assessment..............................................................................................6
1.4 Most commonly used ergonomic tools..................................................................................7
2. RAPID ENTIRE BODY ASSESSMENT (REBA).....................................................................7
3. Steps for Calculation of REBA....................................................................................................9
4. Limitations of the REBA...........................................................................................................11
5. Advantages of REBA................................................................................................................11
6. Why we selected REBA?...........................................................................................................12
7. Evaluation of whole body for postural MSD and risks associated with the task......................12
7.1 Section A - Neck, Trunk and Leg Analysis (Step 1-6)........................................................13
7.2 Section B - Right Arm and Wrist Analysis (Step 7 - 9).......................................................14
7.3 Section C - REBA score calculation (Step 10 - 13).............................................................15
7.4 Analysis................................................................................................................................16
7.5 Improvements.......................................................................................................................16
8. Conclusion................................................................................................................................17
9. Bibliography..............................................................................................................................18

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2.1 Body Posture………………………………………………………………………………..8
7.1 Cutting Body Posture…………………………………………………………………..…12
7.2 Score A Calculation…………………………………………………………………….…13
7.3 Table B Calculation……………………………………………………………………..…14
7.4 Table C & REBA Calculation.………………………………………………………….…15
7.5 MSD Score and Risk……..……………………………………………………………..…16

Table of Figures

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1. Introduction

1.1 Ergonomics
“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” International Ergonomics Association.

The word ergonomics comprises of two Greek word “ergon” which means work and
“nomos” which means laws. Which collectively means “laws of work” or “science of work”.
ergonomics is a systems-oriented discipline which now extends across all aspects of human
activity. [1]

1.2 Ergonomics Assessment

Ergonomic assessment also known as workplace assessment or ergonomic risk
assessment, is the method used to evaluate the risk of musculoskeletal disorders (MSD) because
of gap between workplace design and employee capabilities. Once the physical risk factors are
identified the action is taken to improve the work environment for employees. The aim of the
improvement is to enhance health of employees, improve job performance and job satisfaction.

1.3 Need of ergonomic assessment

Compared to other industries garment industry is normally accepted as safe place for
working. In the garment industry the major risk do not comes from direct exposure with
dangerous hazards, the real risk is of indirect hazards which is effect of repetitive job for prolong
time. The problem may start as a major pain but it can lead to major deices like MSD and can
affect to their daily life routine.

Aiming to reduce these kind of health issues, to create healthy working environment, to
cut the need of professional care, to reduce absenteeism, and increase the productivity garment
industry needs to do ergonomic assessment for every work station.

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1.4 Most commonly used ergonomic tools
 OWAS - Ovako Working posture Assessment System (Karhu, et al., 1977).

 NIOSH - the National Institute for Occupational Safety and Health lifting equation
(Waters, et al., 1993).

 RULA - the rapid upper limp assessment (McAtamney & Nigel Corlett, 1993).

 JSI - the job strain index (Steven Moore & Garg, 1995).

 OCRA - The concise exposure index (Occhipinti, 1998).

 QEC - Quick Exposure Check (Li & Buckle, 1999).

 REBA - the rapid entire body assessment (Hignett & McAtamney, 2000).

 MAC - the manual handling assessment charts (Monnington, et al., 2003). [2]

2. RAPID ENTIRE BODY ASSESSMENT (REBA)

The Rapid Entire Body Assessment (REBA) method was developed by Dr. Sue Hignett
and Dr. Lynn McAtamney, ergonomists from University of Nottingham in England. REBA is a
postural targeting method used to estimate the risks of work-related full body disorders. A REBA
assessment provides a rapid and systematic assessment of a worker's total body postural hazards.
The analysis can be performed before and after an intervention to indicate that the intervention
was effective in lowering the risk of damage. A final REBA score is generated to give an
indication of the level of risk and urgency with which action should be taken.

REBA provides a quick and easy measure to assess a variety of working postures for risk
of WMSDs. It divides the body into sections to be coded independently, according to movement
planes and offers a scoring system for muscle activity throughout the entire body, stagnantly,
dynamically, fast changing or in an unsteady way and where manual handling may happen which
is referred to as a coupling score as it is significant in the loads handling but may not always be
using the hands. REBA also gives an action level with a sign of importance and requires minor
equipment: Pen and paper method. [3]

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 Figure 2.1: Body Posture

Simple tasks were analyzed varying in the load, movement distance and height in order to
define the initial body segments and to establish body part ranges according to the diagrams of
the body part (Group A and B) from RULA.

REBA is most likely to be used by ergonomists and other practitioners. Before using this tool, a
little practice and training is recommended, nevertheless, no former ergonomic skills are
required.

Several studies have indicated the differences between REBA and RULA mentioned that
REBA assessment is suitable for whole body evaluation and best for both static and dynamic
works. There are five levels of actions to indicate the obtained scores. RULA assessment is more
towards upper side of the body. It is best for sedentary and seated works and there are four levels
of actions to indicate the obtained scores.

REBA was improved in the definition of the neutral postures and leg postures from those
of RULA. While RULA defined the neutral position of the wrist, neck and trunk with 0° of
corresponding joint motion angle and changeable leg positions are classified into only two
balanced and unbalanced classes, REBA defined the neutral posture as postures with some
ranges of the angular deviations of the related joints and by classifying leg positions into four
classes.

REBA adapts better than RULA to highly varied workstations. This can be attributed to
the development of RULA within a specific research context that makes it unreliable when
applied in a different context. Additional development of weights was given for diverse items of

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the counting of risk index, combination of items from another checklist and software for palm
computer.

3. Steps for Calculation of REBA

 Step 1: Identify a job

You can pick a work to evaluate by looking at where previous injuries happened, where
operator concerns have been raised, or where quality issues were a concern.

 Step 2: Define and understand the tasks within the job

Interview the operator to learn about the primary work duties, the work demands, and the
operator's perception of the most challenging component(s) of the work.

 Step 3: Identify the tasks within the job you intuitively believe have the highest MSD
risk
Choose the "worst" elements of the assignment to evaluate based on personal observation
and information received from the operator interview.

This should be determined by the most awkward postures present, the greatest force
exerted, awkward postures sustained for a lengthy amount of time, or awkward postures
repeated several times.

 Step 4: Capture the “worst” moment with a photo

Take a snapshot of an operator, for example, lifting a 50-pound package from a pallet on
the floor, or of an operator reaching across the width of a work table to fetch a 25-pound
bundle.

 Step 5: Complete the REBA data collection form

The REBA assesses the entire body, including the upper and lower arms, the
wrist, the neck, the back, and the legs. Compare the position or postures of each body
segment in the photo to those described on the REBA data collecting form. Based on
these postures, the REBA assigns a score to each body segment. It should be noted that if
the upper limbs are doing poorly, they must be assessed individually (right versus left
upper limb).

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  Step 6: Determine the REBA score
The REBA assigns a single final score based on the evaluated posture, force
needs, type of movement, frequency of movement, and coupling within the task. This
single figure, ranging from 1 to 15, shows the operator's work-related MSD risk. It also
adds a sense of urgency to workstation engineering modifications. A score of 8 or above
indicates that the employees executing the task are at high risk of MSD and that
engineering measures are needed.

 Step 7: Continue the job improvement process

If you have a low- to extremely high-risk REBA score, you may need to come up
with strategies to reduce the worker's MSD risk. To do so successfully, begin by
identifying the primary difficulties; next, review the REBA data collecting form to
determine which sections contributed the most points to the total REBA score. Complete
a "5-Why" analysis for each high-risk element found to determine the real core cause of
the problem. Next, concentrate on resolving the issue; brainstorm changes and put them
into action as soon as it is financially feasible.

Check your work after the improvement(s) have been introduced.

Fill out another REBA data collecting form; if your improvements were successful, your REBA
score should be lower. This is a critical stage because it allows the evaluator to check in with the
operators (do they enjoy the change or are they adapting to it) and confirms that the improvement
did not bring new MSD risk factors. Check your work after the improvement(s) have been
introduced. Fill out another REBA data collecting form; if your improvements were successful,
your REBA score should be lower. This is a critical stage because it allows the evaluator to
check in with the operators (do they enjoy the change or are they adapting to it) and confirms
that the improvement did not bring new MSD risk factors.

Finally, you must ensure that the progress is maintained. Train the operators as needed,
revise the Standard Operating Procedure, and solicit employee feedback. Look for ways to
extend the benefits of this upgrade to other workstations as well [4]

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4. Limitations of the REBA

 REBA can only assess one posture at a specific point in time, the results exclude
additional high-risk aspects of the activity.
 To address this, you can perform several REBAs per task or use a task-based assessment
tool to capture the interplay of many MSD risk variables within a task.
 The evaluator must determine which component of the work is the "worst." This may
differ between operators, as well as different evaluators.
 The correct threshold, like other survey-style methods, necessitates some subjectivity.
Consider using motion capture technology to eliminate human error and subjectivity. [5]

5. Advantages of REBA

 The REBA method appeared to be the only method capable of capturing the very
uncomfortable postures that were frequently observed only in the tree nursery sector.
 Can evaluate inanimate or animate loads that are handled on a regular or irregular basis.
 REBA is designed to be a rapid tool. Once you get used to the tool it can be completed
very quickly.
 REBA is meant to be part of a greater ergonomics survey.
 REBA's effective grading system allows you to get a glimpse of the task's highest risk
posture. The score system is divided into four action levels, each of which indicates the
urgency of the inquiry.
 REBA is freely available from developers and associated sources, enables physical
factors to be assessed and allows the assessment of the whole body including lower
limbs.
 It is the best method matched to the needs of occupational safety and health practitioners-
and related professions-who have limited time and resources
 REBA is a screening tool that assesses biomechanical and postural loading on the whole
body.[6]

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6. Why we selected REBA?

 This technique employs a methodical approach to assessing whole-body postural MSD

and ergonomic design hazards related with professional duties.
 A single-page form is used to assess needed body position, forceful exertions, movement
or action type, repetition, and coupling.
 Each of the following body areas receives a score: wrists, forearms, elbows, shoulders,
neck, trunk, back, legs, and knees.
 After collecting and scoring data for each location, tables on the form are utilized to
assemble the risk factor variables, resulting in a single score that indicates the amount of
MSD risk.
 REBA is the modern tool which need less resources and can be done using images for
these many advantages we selected REBA for this ergonomic assessment.

7. Evaluation of whole body for postural MSD and risks associated with
the task.

Figure 7.1: Cutting Body Posture

The REBA worksheet is divided into two body segment sections on the labeled A and B.
Section A (left side) covers the neck, trunk, and leg. Section B (right side) covers the arm and
wrist. This segmenting of the worksheet ensures that any awkward or constrained postures of the

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neck, trunk or legs which might influence the postures of the arms and wrist are included in the
assessment.

7.1 Section A - Neck, Trunk and Leg Analysis (Step 1-6)

Step 1 – Neck position score 2 + 1 (Side bended neck,) = 3

Step 2 – Trunk position score 4 + 1 (Trunk is twisted) = 5

Step 3 – Leg position score 2 + 2 (Bending more than 60 degrees) = 4

Step 4 – Using values from steps 1-3, locate the score for this step in table A = 9.

Step 5 – The load of handling straight knife machine is added in step 4; 9 + 1 = 10

Step 6 – Addition of step 4 and step 5 gives final score of A. The score A is located in table C =
4

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Figure 7.2: Score A Calculation

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7.2 Section B - Right Arm and Wrist Analysis (Step 7 - 9)

Step 7 – Upper right arm is in backward extension (+2) also +1 for upper arm is abducted and+1
for raised shoulder. -1 because operator is leaning 2 + 1 + 1 - 1 = 3.

Step 8 – The lower arm position outside of the neutral range = 2.

Step 9 – A twisting adjustment of +1 is added to the position score of +2= 3.

Figure 7.3: Table B Calculation

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7.3 Section C - REBA score calculation (Step 10 - 13)

Figure 7.4: Table C & REBA Score Calculation

Step 10 –Postural score B is located using values from steps 7-9 = 5.

Step 11 – Coupling score of 1 is added considering it fair.

Step 12 – Score B is calculated and located in table C = 6.

Step 13 – The Activity Score is +1 due to 1 or more parts are held for longer than 1 minute.

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 The Final REBA Score = Table C Score + Activity Score

Final REBA Score = 11 + 1 = 12

7.4 Analysis

Figure 7.5: MSD Score and Risk

In the analyzed position, the final REBA score is 12. The REBA score indicates the very
high risk and need to implement changes. The REBA score indicated high risk of MSD and to
reduce this risk work method changes or/& engineering improvements needs to be done.

7.5 Improvements

 Reduce number of plies in one lay.

 Use proper cutting table.
 Use cutting cloves.
 Use automatic cutter.

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8. Conclusion

Occupational health and safety practices require field observations which can be
performed with the help of feedbacks received from workers and health statistics. In this study,
the cutting room worker is studied for working environment and posture. The ergonomic
assessment tool used to evaluate the posture is REBA. The final REBA score (12) shows that the
selected most critical posture have very high risk and needs immediate changes. The worker may
get some serious physical disorders in near time as the work is repetitive. The ergonomic risk
assessment can protect worker from these significant injuries and musculoskeletal disorder
(MSD). These injuries could be eliminated by scientific ergonomic improvements.

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9. Bibliography

[1] https://iea.cc/definition-and-domains-of-ergonomics/

[2] Ergonomic tools - David, G. C. (2005). Ergonomic methods for assessing exposure to risk
factors for work-related musculoskeletal disorders. Occupational Medicine, 55, 190-199.
Roman-Liu, D. (2014). Comparison of concepts in easy-to-use methods for MSD risk
assessment. Applied Ergonomics, 45, 420-427.

[3] https://uncagedergonomics.com/blog/learn-to-use-the-reba-tool/

[4] http://ergo-plus.com/wp-content/uploads/REBA-A-Step-by-Step-Guide.pdf

[5] https://thescipub.com/pdf/ajeassp.2016.107.118.pdf

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