1. IE 366: Work Systems Engineering
Introduction
Welcome
Introductions
Course
Instructor
GTA
Overview
Industrial and Manufacturing Engineering
IME and Work Design
Challenges for work designers
Example: Reducing Musculoskeletal Disorders
The Work Systems Engineering Process
IE 366 Requirements and Policies
Work Systems Engineering Projects

2. Industrial and Manufacturing Engineering
What is Industrial Engineering?
What is Manufacturing Engineering?
What are the desirable attributes of the Industrial/Manufacturing Engineer?
Industrial and Manufacturing Engineering
Industrial Engineering
application of science, mathematics, and engineering methods to complex system integration and operation
Manufacturing Engineering
specialization of Industrial Engineering that focuses on the making of physical products
often draws heavily on other engineering displines (esp. Mechanical Engineering) for the design or adaptation of equipment
Industrial and Manufacturing Engineers (IMEs) must have
expertise in a wide variety of disciplines
ability to work well with people
broad, systems perspective

3. Industrial/Manufacturing Engineering (IME)
complex system integration and operation
Complex System: set of people, equipment, materials, and information that function together to make products and/or provide services, e.g.,
aerospace
automotive
communications
computers
electronics/semiconductors
financial
food
government
health care
homeland security
manufacturing
retail
transportation
Integration: the “… making up or composition of a whole by adding together or combining the separate parts or elements; combination into an integral whole: a making whole or entire.” Oxford English Dictionary
In IME, requires analysis and design of, e.g.
facilities
material handling systems
manufacturing and other production processes
information systems
communication systems
human-machine interfaces
individual and group workplaces
organizational structures
(continued on next page)

4. Work What is work? Why is it important to IMEs? What is a Work System?
What are the challenges for Work Systems Engineers (i.e., IMEs who design work systems)?
(continued from previous slide's Notes)
Operation: “…condition of functioning, or being operative or active.” OED
i.e., producing products or providing services
IMEs develop, apply, and monitor policies, procedures, and algorithms for
production planning and control
resource allocation and scheduling
personnel assignment and scheduling
quality assurance
inventory control
production management
Work: “ Something to be done, or something to do; what a person (or thing) has or had to do; occupation, employment, business, task, function.” (OED)
Work is at the heart of any complex system.
A Work System is comprised of
Workers (Personnel)
Equipment
Work processes
Challenges for Work System Engineers:
Work System Performance
Designing high-performance work systems.
Enhancing worker performance.
Minimizing worker error.
Worker Safety
Designing safe work systems.
Minimizing musculoskeletal disorders.
Avoiding physiological overloading.
Avoiding occupational injuries and illnesses.

5. IE 366, Work Systems Engineering
Ergonomics
Human Factors Engineering
Work Systems Engineering
Ergonomics
ergon – work
nomos – law, ordinance
ergonomics –
literally, laws or principles of work
the application of scientific principles to the design of safe, effective, and efficient human work (with special reference to the reduction of musculoskeletal disorders)
Human Factors Engineering (considered in more detail later in term)
“… 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 other methods to design in order to optimize human well-being and overall system performance.”
(Definition adopted by the International Ergonomics Association and the Human Factors and Ergonomics Association)
Work Systems Engineering
Human-centered integration of workers (personnel), equipment, and processes for
effective
efficient
safe
production of goods and services, with foc

6. Reducing Musculoskeletal Disorders
Ergonomics
Reducing Musculoskeletal Disorders
Musculoskeletal Disorder: pain or loss of function due to overexertion or repetitive motion, especially
Low back (e.g., related to manual material handling)
Upper extremities (e.g., related to typing, assembly)
Hands
Wrists
Elbows
Shoulders
Magnitude of the Problem
Source: National Research Council (2001). Musculoskeletal Disorders and the Workplace: Low Back and Upper Extremities, Washington: National Academies Press.
70 million physician office visits annually
130 million total health care encounters
outpatient
hospital
emergency room
Potential for long-term disability (but most return to work within 31 days)
Annual cost: $45 - $54 billion
workers’ compensation costs
lost wages
lost productivity

7. Musculoskeletal Disorders of the Lower Back
Load
Anatomy
L5/S1
Problem
Low-back pain
Low-back impairment
Low-back disability
Low-back compensation
Risk Factors
Individual physical factors, e.g., Weight, Physique, Gender
Task demand factors, e.g., Horizontal distance to load, Posture, Repetition
Environmental factors, e.g., Workplace design, Slippery floors
Psychological factors, e.g., Depression, Anxiety
Interventions
Job Design:
reduce manual materials handling (automate)
decrease weight
use 2 or more people where possible
push or pull vs. lift & carry
minimize carrying distance
stacking height < shoulder height
heavy objects at knuckle height
reduce lifting frequency
provide rest periods
use job rotation
provide handles
Method: squat lifting
Worker selection
Supports, braces ??? H

8. Musculoskeletal Disorders of the Upper Extremities
Anatomy
Problems
tendonitis
tenosynovitis
carpal tunnel syndrome
trigger finger
vibration-induced white finger
Risk Factors
Repetition
Excessive force
Poor posture (bent wrists)
Direct pressure on nerves
Vibration
Cold
Poor physical condition
Interventions
Reduce repetition
Reduce force
Keep wrists neutral
Good hand tool design
Proper grip surface
Design for either hand
Reduce vibration
Motorize

9. Hand Tool Design Interventions

10. Human Factors Engineering
… 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 other methods to design in order to optimize human well-being and overall system performance.
Definition adopted by the International Ergonomics Association and the Human Factors and Ergonomics Association

11. Human Performance and Safety In Various Domains
Aviation: aircraft accidents
Medicine: patient injuries and mortalities
Manufacturing: defects
Power Generation and Distribution: blackouts
Surface Transportation: auto/truck accidents
Water Transportation: boat/ship accidents
Workplace: occupational injuries
etc.

12. Human Factors Engineering
considers Human Factors, factors that influence human performance,
Individual Factors, e.g.,
sensory
cognitive
physical
Group Factors , e.g.,
composition
organization
dynamics
Task Factors, e.g.,
number
nature
procedure
Equipment Factors, e.g.,
display colors
control placement and dynamics
Tools geometry
Environment Factors, e.g.,
illumination
temperature
vibration
in an attempt to understand and improve human performance and safety so as to improve system performance and safety.

13. Human Factors Engineering
learns of the effects of human factors on human performance and safety through
Experience (often bad)
Research
and develops and applies principles and guidelines to the design of
Equipment, e.g.,
displays
controls
tools
workstations
Procedures
Job performance aids , e.g.,
manuals
checklists
memory aids
Training programs
Selection programs

14. The Work Systems Engineering Process
Needs,
Problems,
Opportunities
Evaluation
Analysis
Management
Requirements
Performance Data,
Observations
Operation
Design
Design
Specifications
Workers
Implementation
Material
Equipment
Products
Energy
Services
Information
Work Processes
Work System

15. The Work Systems Engineering Process
Needs,
Problems,
Opportunities
Analysis
System Analysis
Environment Analysis
Personnel Analysis
Facilities & Equipment Analysis
Process Analysis & Modeling
Ergonomic Analysis
Failure Modes & Effects Analysis
Requirements Engineering
Evaluation
Checklists
Heuristic Evaluation
Usability Testing
Statistical Analysis
Performance Data, Observations
Management
Planning
Scheduling
Work Assignment
Monitoring
Assessment
Requirements
Operation
Role Playing
Simulation
Full-scale Operation
Observation
Data Collection
Design
Workstation Design
Equipment Design
Procedure Design
Job Aid Design
using Design Principles
Design Guidelines
Work
System
Design
Specifications
Implementation
as (Computer) Model
Mockup
Prototype
Operational System

16. IE 366 Syllabus
(handout)

17. IE 366 Work Systems Engineering Projects
(handout)
Work System: part of a production system consisting of
Work area
Equipment (tools, machines, etc.)
Worker(s)
Work processes
Teams: 3-5 members from same lab section assigned by instructor
Requirements (see handout)
Examples (see handout)
Available Projects
Assignment (see handout)