Physical Ergonomics

Guidebook

Revision : 1
Internal
 Footrests

Recommendations

❑ The seat used at a “high-seated" workstation must be equipped with a

footrest allowing the operator to change posture.

❑ Height and angle adjustment is required for high-seated stations

❑ Height adjustment is compulsory given individual size differences and

preferences

❑ The footrest should be able to be adjusted by operator foot

❑ The surface should be textured to allow for better gripping of the shoe
and wide enough to provide support. Avoid using a surface edge that
will apply localized pressure to a small area of the foot.

❑ Footrest should be wide enough to accommodate some movement by

the operator

❑ For workstations with foot switch, it is wise to integrate such controls

into the footrest to obtain a common height adjustment.

❑ The footrest should be built into the workstation if the station is height
adjustable. If not attached to the workstation, the foot rest must
adhere sufficiently to the floor.

❑ The “standing” workstation support framework under bench can be

utilized as footrest if in proper location (height and depth) and must
ensure operator comfort.

Internal
 Footrests
A footrest is essential beneath a "high-seated“ workstation.

W
Y
H
D

DIMENSIONS TO BE RESPECTED seated high-seated

mm inches mm inches
H ➔ Adjustable height 40-150 2-6 300- 450 12-18
W ➔ Width > 500 > 20 > 500 > 20
D ➔ Depth > 350 > 14 > 350 > 14
Y ➔ Adjustable inclination 0 - 15° 0 – 15°

The footrest in a standing workstation enables the operator to shift weight

from one leg to the other. This ability reduces the stress on the back, lower
legs and feet.

Utilize rounded
raw stock

D
H

DIMENSIONS TO BE RESPECTED standing

mm inches
H ➔ Height from floor 100-150 4-6
D ➔ Depth from edge of work top 150 6

Internal
 Workstation Dimensioning
Product Assembly

Clearance for passing legs and feet beneath

Recommendations :

Sufficient clearance should be provided to ensure lower limb

mobility:

▪Adequate clearance is required to allow legs and feet to be

placed comfortably under the work station.

▪Table thickness should not hinder the operator at thigh level. In

practice, a 30 mm (1.5”) thick worktop often provides an
acceptable compromise between the spatial requirement and
strength properties.

▪Clearance width beneath workstation should allow operator to

swivel seat without encountering obstructions

▪Clearance depth beneath workstation should be sufficient to

allow operator to sit properly

 In the case of "seated" or “high-seated" position, vertical dimensions

are specified for workstation usage by a mixed man-woman
population.

Workstation dimensioning should enable operator to adopt

a suitable posture without leg compression.

Internal
 Workstation Dimensioning
Product Assembly

Maximum
recommended
worktop thickness
< or = 30 (1.5’’)

1030 (41’’)
650 (26’’)

500 (20’’)
Clearance
170 (7’’)

547 (22’’) 547 (22’’)

Clearance
882 (35’’) Clearance
882 (35’’)

Seated workstation High-seated workstation

Minimum lateral clearance width should be :

1100 mm for high-seated posture for clear
1100 (44”)
passage of legs when accessing seat from
either side

Working height Working height

Table height Table height

Space at
Knee
height 210 (8’’)
300 (12’’)

Clearance
226 (9’’)

300 (12’’)
Standing workstation for
Standing workstation bulky or heavy product

Internal
 Working Height
Definitions

❑ Working height
hand height in the working position

❑ Table height
height of the product or sub-assembly bearing level
including the fixture when existing

Recommendations
 Working height should be chosen to ensure an appropriate body position while
meeting vision requirements.

 This choice represents a compromise between requirements for low neck, arm,
shoulder and back loads and vision distance requirements ensuring appropriate
visual control.

 Vertical dimensions should be decreased by 100 mm (4”) for a predominantly

feminine population.

 Optimum working height and incline depend on the task to be performed.

 The table can be inclined or horizontal. An inclined surface often provides the
best solution: the most suitable angle for an inclined surface represents a
compromise between vision requirements, the imposed load on the neck, back
and shoulders and the angle preventing objects from falling. An angle of
approximately 15° is recommended for many precision handling tasks involving
significant vision requirements

 Precision work features a high visual load (vision distance of the order of 30 cm -
12”), accurate positioning (P2 and P3 - reference MTM1, PC-reference MTM2)
and a mill metric degree of accuracy (1.2 cm-1” - reference MTM), this constraint
appearing for at least 30% of the Design Time.

 In the case of high precision work, the vertical dimension must be increased to
lessen the distance between the eyes and the working height.

 In the case of precision work (electronic or component assembly, inspection of

very small parts, cabling or wiring, etc.) or work on bulky loads, an adjustable
table is highly recommended
 Any work with the arms in a raised position should be avoided. Otherwise,
armrests should be provided.

Table height should be defined according to recommended working

height, jig dimension and size of the product to be assembled.

Internal
 Working Height

Task Working Working height

requirement
Position height vs elbow eight

Working
height
H1 =
700 à 750 Working height
Office work
mm at elbow height
28’’ to 30”
H1

Manual work Working

(arm support) height
coordination H2 = Working height
associated 1000 à above elbow
with visual 1100 mm height
surveillance
in same H2 39’’ to 43”
working area

Working
height
Active arm or
H3 = Working height
small object
1000 à at or slightly
movements
1100 mm below
with medium
H3 39’’ to 43” elbow height
precision

Handling of Working
objects that Working height
height H4 =
are large but variable,
800 à depending
not too bulky
1000 mm
or heavy (no on the size
H4 31’’ to 39”
precision of the object
work)

In transfer lines interlinked with a table at constant height, working

height can vary depending on assembly. Choice of table height can
only be a compromise based on the working situation. Working height
needs to be adaptable for a possible standing posture.

Internal
 Working Zones

Definitions

Two Hand Zone

❑ Zone where work can be performed by one or both hands with no
limitations or restrictions

Comfort Zone
❑ Zone of maximum comfort for handling parts and tools while performing a
single hand operation

Acceptable Zone
❑ Zone that can be used for feeding and discharge operations as well as
occasional control actuations or assembly operation when the comfort zone is
insufficient (i.e. assembly workstation)
Risk Zone
❑ Restricted working zone that is to be avoided

Recommendations

 Layout of controls or objects to be manipulated should be defined in

two stages: the horizontal plane and the vertical plane.

 The heaviest objects or those most frequently handled should be

placed in the 2-hand comfort zone.

Part assembly should be performed in the comfort zone. Ensure the

operators are trained to respect the right motion sequence.

Sufficient clearance must be provided to ensure lower limb

mobility, to allow operator to sit properly in front the working
zone and to work in good seated posture.

Internal
 Working Zones
Define position of parts and tools to be handled
based on using them according to required zones

Working zone for seated work station

Risk zone When undertaking assembly

requiring body movement
precision, it is recommended
Acceptable zone Acceptable zone that the 2-hand zone be
centered at an average
415
( 16’’)
distance of 200 mm ( 8’’) from
290 Comfort Comfort
zone
the table edge (150 to 250 mm
( 11’’) zone
– 6” to 10”)
Risk zone 100 ( 4’’)
90
100 ( 4’’)

250 ( 10’’) 250 ( 10’’)

1170 maximum
( 46’’)

Working zone for standing work station

Risk Zone Zones determined as

semicircular for "seated" or
"high-seated" workstations
Acceptable Zone Acceptable Zone become linear for "standing"
workstations, the operator
being able to move in front of
415 the workstation.
16’’
290 Comfort Zone Comfort Zone
11’’

Risk Zone 100 (4”)

100 (4”)

Risk zone

Acceptable
Working zone for equipment assembly zone

Comfort
zone
r = 80cm
80cm
(31”)
(31”) 1600
( 63’’)
Parts
Parts

Product
800
Risk ( 32’’)
zone
Comfort Zone 1500
( 59’’)

Internal
 Workstation Replenishment

Recommendations

 Limit applied forces according to the requirements given in

“Exerted Forces” section

 Limit load to be conveyed according to requirements given in

“Manual Lifting" section

 Allocate a minimum of necessary space for movements and

displacements according to requirements given in “ Workstation
Accessibility" section

❑ It is better to use an inclined surface to reduce reach distance

by operator and to optimize replenishment by water spider.

❑ The design and positioning of boxes, bins and dispensers

must avoid wrist extension or flexion

 Use mobile trolleys for moving parts without carrying them,

provide handling aids for heavy or bulky loads

 Prefer heaviest loads at a height between 800 and 1200 mm

(31” to 47”) (inside comfort zone.)

❑ Use dynamic storage units allowing front pick-up

❑ Train personnel to follow ergonomics material handling

guidelines

❑ Ensure that there is no friction between containers to allow

easy movement

❑ Must consider the size of the hand as well as the size of the
component inside the box when determining dimensional
clearances
Prohibit use of a stepstool or stairs for accessing shelves. A
ramp could be utilized to facilitate lifting and lowering parts,
products or boxes.

Internal
 Workstation Replenishment
Risk zone may only
be used for
extremely light boxes
and occasional use

Comfort zone
300 mm recommended for
(12”) frequent handling of
heavy and bulky
parts*

Acceptable zone
may be used for
handling < twice /
minute

150 Risk zone

mm
(6”)

E1
P

E2 E2 E2

Standard containers
on shelves

Too tight to remove boxes Dispenser Divider guides in place Offset picking stations

Material handling tasks must be designed to minimize the weight,

range of motion, applied forces, and frequency of the activity.

Internal
 Zones of Vision

Definitions (see diagram on next page)

Eye-product to be assembled axis

Main vision axis ➔
Zone around main vision axis; vision can be
Visual comfort zone ➔
displaced within this zone by moving the eyes only.

Zone in which small head movements are

Acceptable zone ➔ required to allow vision to identify a component.
This zone can be used when the comfort zone
is insufficient.

Zone only to be used under certain conditions

Arduous zone ➔ (e.g. light signal accompanying acoustic signal).
Major head movements are required to scan
this zone

Recommendations

❑ Ensure that nothing forms an obstruction between the eye and the
visual information.

❑ In the case of luminous digital display, it is preferable to use figures

formed by electroluminescent diodes.

❑ Utilize adequate color zone contrast when picking up very small

parts.
Visual inspection
❑ The efficiency of the visual inspection will depend on :
▪ the environment
▪ the number and frequency of breaks
▪ the number of defaults
▪ the knowledge of the quality issue
▪ the training given

The reliability to detect defects through visual inspection varies

substantially from inspector to inspector. Poka Yoke must be
implemented to either prevent defects or automatically reject defects.

Internal
 Zones of Vision
Respect visual range zones defined by main vision axis as
determined by most frequent working zone

Main vision axis

Visual comfort zone

Acceptable zone Acceptable zone

B 15° 15°
V
A
45° 45° Occasional
Occasional
observations
observations

Head 30°
movement

B
A

30°

Eye
movement
30°

Body
movement
A ➔ Product being assembled
B ➔ Visual indicator to be viewed at each cycle
C ➔ Cyclic feeding of parts required for product assembly
V ➔ Power screwdriver

Frequent movements of the head in all directions to scan the

zone can cause fatigue and neck strain.

Internal
 Visual Range

Visual range ➔ Response characteristic to the visual requirement of the

task. It is defined by the viewing direction and the "eye -
task" distance.
Recommendations

 The viewing direction and the "eye – task" distance can have an
adverse influence if they are inadequately considered or if
consideration of their interaction is overlooked.

 Avoid repeated head movements required for reading indicators.

Preferably, position these indicators in the visual comfort zone with
respect to the main vision axis and limit placement of objects to be
picked up to the "acceptable zone".

 Eye – product distance should not exceed 50 cm (20”) for

assembly operations, it can be reduced to 30 cm (12”) for small parts
or motion precision requirement.

 For reading purposes, eye – character distance is defined

according to script dimensions.

 Vision zone depth should be determined with respect to size of

items to be read or recognized.

Utilization of a camera for viewing zones at high level in the

warehouse or DC for picking with PIT is recommended

Visual requirements can cause postural constraints

Internal
 Chapter 11

Visual Range
The viewing distance has an influence on the characters size to be used
for best legibility, colors and contrasts shall be chosen accordingly.

D < 50cm (2’)

Caution
E
E Height of characters
> 3 mm (0.12”)
From font size 10 points
Caution
D = 50-80cm (2’-3’) Caution
Caution
E
E Height of characters
> 3,5 mm (0.14”)
YES
D = 80-125cm (3’-4’)

D = 125-200cm (4’-6’)
E
E Height of characters
> 4,5 mm (0.18”)
From font size 22 points
Caution
Caution
Caution

D = 200-315cm (6’-10’)
E
E Height of characters
> 6 mm (0.24”) Caution

NO

D = 315-500cm (10’-16’)
E
E Height of characters
> 9 mm (0.35”)
From font size 36 points

E
E Height of characters
> 14 mm (0.55”)

D = 500-800cm (16’-26’)

D = 800-1200cm (26’-39’)
E
E Height of characters
> 23 mm (0.9”)
From font size 80 points

E
E Height of characters
> 36 mm (1.4”)

Internal
 Chapter 12

Screen and Keyboard

Size, location and arrangement of workshop computer screen,
keyboard and software characteristics influence operator
comfort and performance

Recommendations

 It’s recommended to have just one screen in one workstation. If

there is more than one application and the screens cannot be
combined, it is important to locate the main screen in front of the
user; additional screens should be at the same level if possible.

 Size of the screen must be appropriate for application, enabling

users to read the contents from the desired distance.

 To limit reflection, screen should not be located and oriented to

avoid incidental light from any natural or artificial light source.

 Screen position and distance should comply with visual

requirements (refer to visual zone & visual range).

 The screen should be adjustable for operator comfort.

 An external keyboard is a better option than a touch screen if data

needs to be entered, however keyboard usage should remain
limited; If extensive data entry is required, operating conditions
should be arranged following office work setup.

Display must be relevant to the task and interface must be

limited in complexity and user-friendly.

Internal
 Screen and Keyboard
Under Industry 4.0, the use of screen in the shop floor is inevitable and
is growing. However we should not overcrowd the space with screen. If
there is more than one application in a single area / workstation, they
should be combined into a single screen.

1500 – 1700 mm

900 – 1100 mm

• Size of screen should be determined based on reading distance and font character
vertical dimension (refer to Visual Range - Chapter 11)
• Maximum reading distance is 2.8 meters
• Minimum screen size recommendation is 32 inches @ 2.0 m, 65 inches @ 2.8 m
• Work station minimum screen size recommendation is 17 inches (reading distance
<80 cm/31”)
• Display for terminal screen should allow tilt between 0°- 20°

To prevent overcrowding, do not install too many screens in a

single workstation. Operator can only focus on one screen at
any one time.

Internal
 Positioning of Controls

Recommendations

 Manual controls used at each cycle should be located in

acceptable gripping zones.

 The degree of force to be applied should be considered, when

determining the position of controls requiring application of force (e.g.
press lever).

 Controls used frequently should always be located near the visual

task.

 A control used for emergency operation should be capable of

actuation in a very short time.

 When a control requires only a single hand, position it on the side

of the limb required. Provide means of adjustability to satisfy right-
handed / left-handed operation if possible.

 Controls should have a low probability of being actuated

accidentally. Ensure body movements (amplitude and direction) are
compatible with required arm movements.

 Controls should located according to:

▪ expected operator response time
▪ potential of emergency reaction (activate E-stop)
▪ operator learning curve
▪ handling constraints
Arrangement of controls can minimize postural constraints but
in some cases can increase the risk of identification errors.
Controls must be protected if they could be accidentally
activated.

Internal
 Positioning of Controls
Recommended dimensional ranges are minimum requirements.
Other requirements (visual, movement information, etc.)
should be considered when designing the workstation.

Controls mounted Controls mounted

on vertical panel on horizontal panel

28”

20”

12”
8” 8”

2” 2”

65”

55”

47” 47”

39”
35” 35”
31” 31”

2” 2”

Recommended heights for standing work are identical for high-seated posture

Whenever possible, place controls used for emergency in

similar position on the workstation (height, distance, horizontal
or vertical) to facilitate locating and to reduce the operator
reaction times.

Internal
 Two-Hand Controls

Definition

➔ Two hand control: a device requiring a least one simultaneous

action using both hands to trigger and maintain, as long as a
dangerous situation exists, all machine operations and which
therefore constitutes a protection measure only for the person who
actuates it.

Recommendations
 Use of horizontally positioned finger tip “sensor” controls or
"mushroom head" pushbuttons (type XB Telemecanique)

 Fingertip pressing should be prohibited for repeated operation.

 Control devices should be stable under normal operation.

 When calculating the safety distance between operating devices

and danger zones, take into account:
▪ hand/arm speed,
▪ control shape and layout,
▪ device response time,
▪ time between signal interruption and risk disappearance.

 Two hand control has to be installed in comfort zone for repeated

operation.

The set of recommendations should be complemented by

accurate analysis of the work situation and consideration of
relevant standards. Two hands controls are utilized to protect
the operator from accident . To protect employees passing by,
screens or other guardrails must be provided.

Internal
 Two-Hand Controls
Define two-hand control position based on risks of
reaching danger zones

 Recommended spacing of
controls (L) 550 mm ( 22’’)

Positioning of controls on a
horizontal or near horizontal
surface should be positioned
close to the working height

 In the case of non-repetitive work

only, fit a protection collar around
operating controls mounted on a
vertical or virtually vertical surface.

If control spacing is less than 550

Wire Bar mm ( 22’’), use one or more screens
ensuring the controls cannot be
simultaneously touched by a device
comprising a 300 mm ( 12’’) long (Ø
< 5 mm – ¼ inch) rigid rod and a
250 mm ( 10’’) long cord. Rod
represents the forearm and cord,
the hand. Apply this device in every
possible position.

It is recommended to use sensors where you simply lay your fingers

across a pad to avoid the use of collars requiring forceful push.

Internal
 Two-Hand Controls

Selection criteria

➔ Nature of risks) present

 a two-hand control device is unsuitable for machines subject to ejection
risks or harmful physical effects.
➔ Number of operators
 if several operators are required, it is better to turn to other protection
means (photoelectric barrier, guardrails)
➔ Type
 sensitive or mechanical control
➔ Response time
 calculate minimum safety distance between cubicle and start of danger
zone
➔ Palm force
 force must be least 5 N (1.1 Ibf) and no more than 20 N (4.5 Ibf)

➔ Control parts
 recommended diameter: 60 - 80 mm
( 2’’ to 3”)
 color other than red

Minimum safety distance

This distance is calculated using the following formula:

- in cm S = 160 ( t1 + t2 ) + C
- in inches S = 63 (t1 + t2) + C
S = safety distance in cm - with S as minimum distance = 10 cm ( 4’’)
t1 = overall device response time in seconds (manufacturer specifications)
t2 = machine shutdown time in seconds
C = additional distance of 25 cm ( 10’’)
If or when the device is actuated, a suitable protective screen prevents entry
into the danger zone, this additional distance may be zero.

“Soft Touch”, a fully passive system, keeps the spot welder

operators safe by closing the electrodes under low force.
(Unitrol supplier)

Internal
Two-Hand Controls

Application examples

Sensor control
(triggered by finger
presence)

Recommended

Pressure control
(triggered by palm
pressure)

Acceptable

Pressure control
(triggered by fingertip
pressure)

Prohibited

Internal
 Foot Controls

Recommendations :

 Use of foot switches at each cycle can increase task arduousness

if the following basic rules are not followed:
▪ Heel must maintain contact with the floor or footrest
▪ Large leg movements should be avoided
▪ Multiple foot positions should be available on foot switches
▪ Foot switches should be able to be positioned in relation to
individual

❑ Shifting posture of standing and high-seated is not recommended

with footswitches used

❑ If two foot switches are utilized on a workstation they must be

positioned so that there will be no risk of error

 Utilization of safety shoes should be considered in the design of

the foot switches; allow enough toe room to properly activate the
switch

 Utilize manual hand controls if possible. Foot switch should be a

secondary choice

Foot switches must be protected if the potential for accidental

activation exists. Frequent use of foot switches in a standing
position can cause postural constraints.

Internal
 Foot Controls

Example of a double foot control utilized on a high-seated workstation

Example of a safety foot control utilized on a standing workstation

If possible avoid use of foot switches for short cycle and

repetitive operation.

Internal
 Workstation Clearance and Accessibility

Recommendations:

 Avoid all obstructions in the hand placement zone

 Use containers which facilitate easy parts pick-up (dispensers,

shallow boxes, etc.)

 Provide enough space for pushing chair away from table to

allow operator to easily leave the workstation

 Round corners of jigs forming recesses with which operator

will be in frequent contact

 Assembly or product volume can cause congestion problems:

In this case, a suitable solution should be sought (lifting table,
rotating platen, etc.)

 Ensure dimensioning of accesses and traffic corridors around

workstation to accommodate movements to be undertaken (parts
delivery, trolley usage, passing of one or several people)

 Provide adequate storage and holding areas to limit

congestion and allow free passageway

 Use workstation gravity skate wheel conveyor or similar to

avoid material cross-flow and reduce operator movements

 Provide pedestrian overpass or cross way through the line for

large cells or long conveyors

Dimensions shown on next page are recommended ‘minimums’: To

maximize worker productivity and comfort, in some situations the minimum
will not be good enough for best access and clearance

Allow enough work area to prevent all operator

movements from collision and obstruction.

Internal
 Workstation Clearance and Accessibility

Min. 1600 mm
Min. 800 mm (63’’) from the edge
( 31’’) of the tables

Cell accessibility must be

Distance from work station to rack 800 mm/31” Distance inside the U line

Diagrams illustrate
product cart
movement clearance
and aisle/access
clearance between
rack and/or
production tables in
work areas

Hand access Outstretched hand Fist

H no wrist rotation
W minimum (mm) 120 ( 5’’) 120 ( 5’’)
H minimum (mm) 60 ( 2.5’’) 120 ( 5’’)
W
with wrist rotation
 minimum (mm) 120 ( 5’’) 120 ( 5’’)

Forearm access
Rectangular opening W minimum = 150 ( 6’’)
H minimum = 150 ( 6’’)
W H Circular opening  minimum = 150 ( 6’’)

2-handed access to 1 point at distance D < 500 ( 20’’)

W minimum (mm) = 3/4 D + 150 ( 6’’)
D HI
H minimum (mm) = 150 ( 6’’)
W

Internal