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Common manipulator-assisted materials handling tasks were performed in a laboratory simulation at self-selected and faster (paced) speeds. The effects of pacing on peak hand forces, torso kinematics, spine moments and forces, and muscle antagonism were determined, along with any influences of several task variables on these effects. The faster trials were performed 20% more rapidly than the self-paced trials. It was found that (a) achieving this level of performance required 10% higher hand forces and 5%-10% higher torso moments, (b) consistent torso postures and motions were used for both speed conditions, and (c) the faster trials resulted in 10% higher spine forces and 15% higher levels of lumbar muscle antagonism. On whole, these results suggest a higher risk of musculoskeletal injury associated with performance of object transfers at faster than self-selected speeds with and without a manipulator. Further analysis provided evidence that the use of manipulators involves higher levels of motor coordination than do manual tasks. Several implications regarding the use of material handling manipulators in paced operations are discussed. Results from this investigation can be used in the design, evaluation, and selection of material handling manipulators.

In this paper we describe a new scheme for empirically investigating the effects of task factors on three-dimensional (3D) dynamic postures during seated reaching movements. The scheme relies on an underlying model that integrates two statistical procedures: (a) a regression description of the relationship between the time-varying hand location and postural angles to characterize the movement data and (b) a series of analyses of variance to test the hypothesized task effects using representative instantaneous postures. The use of this scheme is illustrated by an experiment that examines two generic task factors: hand motion direction and motion completion time. Results suggest that hand motion direction is a significant task factor in determining instantaneous postures, whereas a distinctive difference in the time to complete a motion does not appear to have a significant effect. We discuss the concept of an instantaneous posture and its utility in dynamic studies of movements, some insights into human reaching movement control strategy, and implications for the development of a 3D dynamic posture prediction model.

Although injuries related to postural stability are prevalent, ergonomic job analyses traditionally have not addressed stability issues. In this research functional stability limits are quantified for persons standing in extreme postures under various external load and foot positioning conditions. Participants were asked to lean and displace their center of gravity (COG) as far as possible in eight directions to the sides and front of the body. Stability measures based on these COG displacements were calculated. All controlled variables significantly affected the stability measures. When standing unladen, participants extended their COG to within 99% of their theoretical maximum. Movement was much more restricted when handling a load (89%), especially when holding it with one hand on the shoulder (84%). On average, increased separation of the feet in a particular direction resulted in larger COG displacements in that direction. The results are discussed relative to their effects on balance and stability modeling.

The use of material handling devices (MHDs) to eliminate the repetitive lifting components of industrial jobs has introduced a new set of issues for industrial ergonomics. Worker performance and safety when using MHDs depends on the mass and distance moved, the asymmetry of the postures, and the positioning accuracy required at each endpoint of the movement. Ten participants moved loads of up to 68 kg and placed them in targets of different sizes. In one experiment they maintained sagittally symmetric postures; in the another they were required to rotate their entire body 180° to complete the task. Measured peak push and pull hand forces ranged from 40 to 120 N and peak hand velocities ranged from 1.0 to 1.6 m/s in both studies. Psychophysical ratings were significantly correlated with peak push and pull hand forces but not peak velocity. Averages of peak hand force and velocity are used to develop some general recommendations for improved implementation of MHDs in industry.

This study investigated effects of flooring on perceived tiredness, fatigue, and discomfort for workers required to stand while performing their jobs. Eight flooring conditions of varying thickness and stiffness (including one shoe insert) were evaluated by workers who answered a questionnaire. Questions were asked regarding whole-body tiredness. leg fatigue. and discomfort. Flooring had a significant effect on workers' perception. In general softer materials caused less perceived tiredness; however, one extremely soft floor resulted in higher ratings of tiredness. Similar results were found for material thickness. The shoe insert condition showed low tiredness ratings as compared with most floors, including one made of the same material. The discomfort ratings indicated that harder flooring materials caused greater discomfort. Discomfort of the lower extremities tended to decrease as distance from the floor increased. Low back discomfort was found for hard flooring surfaces.

Simple discrete arm movements were studied before and after muscle exertion. Results showed that fatiguing muscle exertions do not seem to alter the speed of initiation of responses but do alter movement time, particularly for movement associated with final corrective action.

A set of push/pull experiments was performed by six men and women of varying anthropometry who were asked to exert maximal one-handed and two-handed push and pull forces on a load cell set at three different heights (67, 109, and 152 cm). They were each permitted to experiment with their postures to determine that which they sensed would permit the largest push or pull force, though no direct feedback was given as to their actual performance. Once they achieved what they believed to be their optimal posture, sagittal-plane photographs were taken. The angles of major body joints were then recorded along with the isometric force produced. It is shown that foot placement, handle height, and body postures affect push and pull force capability in a manner that is reasonably logical, using biomechanical concepts. It is proposed that future biomechanical models of push an pull strengths and workplace layouts must be carefully assessed with reference to the postural variations reported.

Many workers perform manual assembly tasks or use hand tools while the hands are postured above the shoulders or to the side of the body. Experiments were conducted to study the sensitivity of speed-accuracy movement performance to a wide range of hand locations around the shoulder under various levels of hand loads, ratios of work to rest, and task durations. Subjects performed a spatially constrained stylus-to-hole Fitts reciprocal movement task designed to simulate high-incentive manual assembly operations while providing basic information regarding changes in human move and positioning capabilities. Significant decrements in movement performance occurred when hands were postured above shoulder level. Move and positioning times increased 15.3% and 26.5%, respectively, with elevation of the hand from −15 to 60 deg respective to shoulder level. Posturally based decrements in movement capability were unrelated to differences in subject strength capability found among test postures. The consequences of elevated arm postures on human move and positioning capability are presented along with workplace design and methods recommendations for job designers facing work-height decisions in manual assembly environments.

The rapid adoption of software to simulate human reach motions in the design of vehicle interiors and manufacturing and office workstations has required a sophisticated understanding of human motions. This paper describes how more than 3000 right-arm reaching motions of a diverse group of participants were captured and statistically modeled. The results demonstrate that stature and age have a larger effect than does gender on reach motion postures for motions chosen by the participants while reaching to targets placed throughout a typical automobile interior. We propose that these methods, models, and results can assist the further development of human motion simulation software for ergonomic purposes, such as for the design or evaluation of vehicle interiors or industrial workplaces, to ensure that various population groups are physically accommodated.

A laboratory study was conducted to assess the effects of lift angle on biomechanical stresses to the musculoskeletal system, and in particular, on the lower back. Male subjects were required to lift four different tote boxes from the floor to a height of 0.81 m using two different lifting techniques. Maximum acceptable weights were determined using a psychophysical method. The motion trajectory of lift was studied by means of stroboscopic photography. Moments and forces at various body joints were computed using a biomechanical strength model. Maximum acceptable weights were 16% (range = 9 to 23%) greater for the free-style lifting technique as compared with the squat method of lifting. There were large differences between the maximum acceptable weights and the "maximum permissible limits" recommended by NIOSH. The results showed that the subjects pulled the load toward the body when lifting psychophysically determined maximum weights. The lift angle increased with an increase in box width. The lift angle was greater for the free-style lifting method as compared with the squat lifting technique for lifting compact loads. Lifting at an angle resulted in a decrease in moment at the elbow, shoulder, L5IS1 disc, and hips, and an increase in moment at the knees and ankles. The estimated compressive force on the lumbar spine was, on the average, 11% lower for lifting at an angle as compared with a straight vertical lift.

Objective: To investigate the relationship among friction, applied torque, and axial push force on cylindrical handles. Background: We have earlier demonstrated that participants can exert greater contact force and torque in an "inward" movement of the hand about the long axis of a gripped cylinder (wrist flexion/forearm supination) than they can in an "outward" hand movement. Method: Twelve healthy participants exerted anteriorly directed maximum push forces along the long axis of aluminum and rubber handles while applying deliberate inward or outward torques, no torque (straight), and an unspecified (preferred) torque. Results: Axial push force was 12% greater for the rubber handle than for the aluminum handle. Participants exerted mean torques of 1.1, 0.3, 2.5, and —2.0 Nm and axial push forces of 94, 85, 75, and 65 N for the preferred, straight, inward, and outward trials, respectively. Left to decide for themselves, participants tended to apply inward torques, which were associated with increased axial push forces. Conclusion: Axial push force was limited by hand-handle coupling — not the whole body's push strength. Participants appeared to intuitively know that the application of an inward torque would improve their maximum axial push force. Axial push forces were least when a deliberate torque was requested, probably because high levels of torque exertions interfered with the push. Application: A low-friction handle decreases maximum axial push force. It should be anticipated that people will apply inward torque during maximum axial push.

Objective: The effects of handle friction and torque direction on muscle activity and torque are empirically investigated using cylindrical handles. Background: A torque biomechanical model that considers contact force, friction, and torque direction was evaluated using different friction handles. Methods: Twelve adults exerted hand torque in opposite directions about the long axis of a cylinder covered with aluminum or rubber while grip force, torque, and finger flexor electromyography (EMG) were recorded. In addition, participants performed grip exertions without torque, in which they matched the EMG level obtained during previous maximum torque exertions, to allow us to determine how grip force was affected by the absence of torque. Results: (a) Maximum torque was 52% greater for the high-friction rubber handle than for the low-friction aluminum handle. (b) Total normal force increased 33% with inward torque (torque applied in the direction fingertips point) and decreased 14% with outward torque (torque in the direction the thumb points), compared with that with no torque. Consequently, maximum inward torque was 45% greater than maximum outward torque. (c) The effect of torque direction was greater for the high-friction rubber handle than for the low-friction aluminum handle. Conclusion: The results support the proposed model, which predicts a large effect of torque direction when high-friction handles are gripped. Application: Designing tasks with high friction and inward rotations can increase the torque capability of workers of a given strength, or reduce required muscle activities for given torque exertions, thus reducing the risk of fatigue and musculoskeletal disorders.

Objective: The aim of this study was to determine how hand space for manual insertion of flexible hoses is affected by insertion method and force. Background: Adequate space is needed during assembly tasks in which workers join parts together with their hands. Hose installations are an example of such a task. Hand clearance envelopes for insertion tasks that involve cylindrical objects, such as a hose, are currently unavailable in the literature. Methods: Participants inserted a flexible 25-mm rubber hose onto a stationary flange using simulated methods similar to those observed in field studies of automotive assembly tasks. Markers placed on the back of the hand and wrists were used to measure postures during the insertion task. Results: Hand clearance envelopes for high-force insertions were significantly larger across methods by an average of 15% for both male ( p < .05) and female ( p < .01) participants. Rocking insertions resulted in the largest hand clearance envelopes compared with other insertion methods. Rocking and twisting the hose resulted in mean increases in the cross-sectional area of the hand clearance envelopes of 35% and 24%, respectively, compared with the straight push. Differences were significant ( p < .05) for male and female participants for both bead height conditions. Conclusion: Both required insertion force and method affect hand clearance envelopes during simulated insertions. Application: These methods can be used by engineers to determine if there is adequate clearance for the hand to grip selected objects.

Materials handling tasks in industry are rarely performed in the midsagittal plane. Often these tasks, labeled nonsagittally symmetric or asymmetric lifting tasks, can be expected to lead to an unequal distribution of forces between the left and right sides of the body. Because of the large number of muscles capable of resisting loads in the torso, researchers are forced to make simplifications when using biomechanical models to estimate mechanical loading of the spine during such tasks. Simplifications and assumptions regarding the coactivation of antagonistic muscles are frequently used because sufficient experimental data do not exist. The present study was designed to quantify coactivation of the trunk musculature in response to applied asymmetric loads. This load was varied in direction from an anterior midsagittal plane orientation to a posterior midsagittal plane orientation in 15-deg increments. The results showed little coactivation when the applied load directions were anterior and within 45 deg of the midsagittal orientation. When load directions were greater than 45 deg, coactivation was quantifiable in ipsilateral and posterior muscle groups.