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RENAULT 2002 Origin: PEGI Renault Page: 1 / 55

Guide of help of the Ergonomics ofindustrial machines and installations

GE75-021R /B________________________________________

Guide________________________________________

Status Executory

Important Note : This document has been translated from the French. In the event of any dispute, only the Frenchversion is referred to as the reference text and is binding on the parties.

Object ! To help designers to interpret exactly the texts of the European directives and theexisting norms in the field of ergonomics.

! To capitalise the satisfactory solutions.

! To list the main international, European and French norms to be respected in the fieldof ergonomics.

This document will be periodically updated under the responsibility of Department 0814,according to the significance of regulatory, normative or technical developments.

The present document is not contractual between Renault and itssuppliers.

Application field All Renault Automobiles sites in the world

Issued by 0814 - Working Conditions Department

Confidentiality Not confidential

Approved by Function Signature Application date

M Ferchal Head of Department 0814 03/2002

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Version record

Version Update Subject of important modifications Editor

A 10/2000 Creation (1) M. Sailly 0814

B 03/2002 Update of sheets 35 and 36Update of the ergonomic analysis sheet (Pages 85 to 90)

M. Sailly 0814

Replaces

Made available Internally on Intranet: http://gdxpegi.ava.tcr.renault.fr

Externally on Internet: www.cnomo.comE-mail: [email protected]

Documents quoted Regulation :

International : ISO 10075-2, ISO 7730.

European : EN 1837, EN 294, EN 547-1, EN 547-2, EN 563, EN 60073, EN60447, EN 61310-1, EN 614-1, EN 894-1, EN 894-2..

French : NF X 35-103, NF X 35-104..

CNOMO :

Renault : EB75.81.325, EB75.82.125.

Other internal docs : Renault ergonomic analysis method.

Other external docs : ND 2052.

Codification ICS: 13.110; 13.180; 17.140.20

Class E75

Key words Scurit des machines, prvention des risques, ergonomie, machine safety, accidentprevention, ergonomics

Language English

(1) Have collaborated in writing this document

Service Name Service Name

09441 M. Brochard 00845 M. Peron09645 M. Boulary 09552 M. Renoux65911 M. Decoster RVI Mme RichardSTA M. Dourlens 66050 M. TabarlyFASA M. Gonzalez 65912 M. Vernhet09346 Mme Goubin09342 Mme Le Prvost

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SummaryPage

1 Presentation of the document........................................................................................................... 4

2 Glossary ............................................................................................................................................. 4

3 Design procedure...............................................................................................................................4

4 General design................................................................................................................................... 5

F1 - Implantation and design of means and equipment............................................................................. 6

F2 - Access to work stations and places of work....................................................................................... 8

F3 - Isolated work station........................................................................................................................... 9

F4 - Signalling measures and service components ................................................................................. 10

F5 - Functional dimensions of equipment................................................................................................ 11

F6 - Protective equipment........................................................................................................................ 12

F7 - Documentation.................................................................................................................................. 13

F8 - Noise................................................................................................................................................. 14

F9 - Lighting.............................................................................................................................................. 15

F10 - Thermal atmospheres..................................................................................................................... 17

F11 - Cleaning work stations.................................................................................................................... 18

F12 - Operating installations - Relevance of information......................................................................... 19

F13 - Operating installations - Right-handed and left-handed operators................................................. 21

F14 - Operating installations - Layout of control system components..................................................... 22

F15 - Operating installations - Colours of signalling and control measures ........................................... 23

F16 - Operating installations - Respect of conventions ........................................................................... 24

F17 - Operating installations - Choice of display measures .................................................................... 26F18 - Operating installations - Analogue display ..................................................................................... 27

F19 - Operating installations - Choice of signals ..................................................................................... 28

F20 - Loading and unloading parts - Tempo of the operator ................................................................... 29

F21 - Loading and unloading parts - Postures......................................................................................... 30

F22 - Loading and unloading parts - Gripping parts ................................................................................ 31

F23 - Loading and unloading parts - Handling efforts.............................................................................. 32

F24 - Controlling the parts - Information and means ............................................................................... 33

F25 - Controlling the parts - Postures, gripping, efforts ........................................................................... 34

F26 - Changing tools and equipment - Information.................................................................................. 46

F27 - Changing tools and equipment - Postures, gripping, efforts .......................................................... 37

F28 - Changing tools and equipment - Openings and access holes ....................................................... 39

F29 - Maintenance or settings - Executing a function.............................................................................. 40

F30 - Maintenance or settings - Spaces, openings and access holes .................................................... 41

F31 - Maintenance or settings - Efforts.................................................................................................... 42

F32 - Supply and evacuation of consumables and waste - Postures and efforts................................... 43

F33 - Repetitive assembly operations - Diversity and complexity ........................................................... 44

F34 - Repetitive assembly operations - Regulation ................................................................................. 46

F35 - Repetitive assembly operations - Postures .................................................................................... 47

F36 - Repetitive assembly operations - Efforts ........................................................................................ 48

5 List of documents cited ................................................................................................................... 49

Appendix 1: ergonomic analysis sheet ..............................................................................................50

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1 Presentation of the document

This guide consists of sheets containing the following themes:

" the rules to respect, reported in the "ergonomics" conformity statement of Renault norm

EB75.82.125.

" the normative specifications,

" listing the normative documents which can act as a reference," extracting the main information from these documents,

" recommendationsresulting from the Renault know-how and experience in this field.Although they provide tried and tested solutions, these Renault comments should not preventthe provision of more efficient, more simple and/or less costly solutions perfected by thesuppliers

2 Glossary

The following definitions are taken from the European norms.

Work activity: any activity effected by the operator in order to achieve the objectives of the work

system.Signalling measure:information presentation measure which transmits visual, audible or tactile signals

to an operator.

Work means: tools, machines, vehicles, apparatus, furnishings, installations and equipment used in the

work system.

Operator: the person (people) responsible for operating, tuning, servicing, cleaning or repairing amachine.

Work component: part of the control system which responds directly to an action of the operator, forexample to pressure exercised by the latter.

Work station: for a given operator, the combination of work equipment in a work space surrounded bythe working environment constitutes the work station for this operator.

Work system: the work system consists of the person and work means,acting together in the workprocess in order to effect a task, within the work area in the work environment,according to the completion conditions for the taskto be effected.

Task: activity(ies) necessary to obtain the result set by the system.

3 Design procedure

Normative specifications: EN 614-1 5

The design process can be seen to proceed in 4 main stages (see table below).

At Renault, these stages correspond to:

" the milestone phases of the projects,

" the corresponding socio-technical milestone phases for anything concerning ergonomics.

Design process(EN 614-1)

Project milestones Socio-technical milestones(ergonomics)

Phase 1 : Elaboration andclarification of specifications.

1. Explanatory and preparatoryphases (milestone: pre-contract).

1. Ergonomic studies of existingelements. Proposal ofobjectives.

Phase 2 : Preparation of designplan(s).

2. Envelope study (milestone:contract).

Elaboration of ergonomicobjectives.

Phase 3 : Preparation of detaileddesign.

3. Detailed study. 3. Detailed study.

Phase 4 : Implementation. 4. Installation and start-up. 4. Reception, improvements.

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Norm EN 614-1specifies certain points concerning the process of taking ergonomics into account

Phase 1Define the organisationalobjectives

! The design of work equipment should follow the setting oforganisational objectives relating to the work process and the workequipment should constitute an integral part of the work process.

Identify the characteristicsof the operators.

" The demands of the operator should be specified at this first stage:identify the specific characteristics of the operators who use theequipment.

Phase 2

Effect an analysis of futurework.

Involve the future users ofthe equipment.

" The initial specifications of the operators' demands should take intoaccount:" the results of the analysis of operators' activity on the machines

to be modified or, in the case of new machines, on similarmachines,

" the distribution of functions between the work equipment and theoperators,

" the tasks which the operators will have to execute using the work

equipment," the interactions between the operators and the work equipment.

" The users have an important role to play from this stage onwards.

" When the demands imposed on the operator are outside theacceptable ergonomic levels, the design plan should be reviewed.

Phase 3Take into accountergonomic principles andsocial and organisationalfactors.

" For the detailed design to represent the best compromise betweenthe technical study and the demands of the operator, referencemust be made to ergonomic principles. Other factors must also betaken into account, such as work satisfaction and organisationalquestions.

Effect work analyses for thedesign of interfaces." To better design the interface between the operator and the work

equipment, task analyses should be effected, to determine what isexpected of the operator and to take decisions regarding theinformation to be supplied to the operators.

" The detailed design should be subject to successive improvementsuntil the definitive solution can be expressed in the form of detailedspecifications.

Compile the documentation." When the design solution has been decided, the documentation

must be compiled, for example: maintenance manual, userinstructions.

Phase 4Validate with future users" It is recommended that:

" the equipment be subjected to user tests," the documentation be evaluated with them.

4 Rules of conception bound to the ergonomics

See following pages

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F1 - Implantation and design of means and equipment

The implantation and general design are consistent with the methods of use. They allow:

the following activities to be effected, strictly limiting the machines down-times :

loading and unloading parts, controlling the parts, changing tools and equipment,maintenance and settings, supply and evacuation of consumables and wastes.the execution of the task to be optimised, limiting movement and ensuring goodvisibility of the installation.

Normative specifications

EN 614-1( 4)

Respect of ergonomic principles applies not only to the intended use of the work equipment but also itsinstallation, setting, maintenance, cleaning, repair and transport.

The design is essentially focused on the interaction between the operator and the work equipment and

consequently the distribution of the functions and actions between the operator and the work equipment.The objective pursued consists in designing a work system adapted to human possibilities, limits and needs.

As a result, the design process should integrate a task analysis.

EN 614-1( 5)

The design of the work equipment should follow the setting of the organisational objectives relating to the workprocess.

The initial specifications of the operators' demands should take into account the following elements:

! the results of the analysis of operators' activity on the machines to be redesigned or, in the case of newmachines, on similar machines,

! the distribution of functions between the work equipment and the operators,

! the tasks which the operators will have to execute using the work equipment,

! the interactions between the operators and the work equipment.

Recommendations

Principles to be respected

! The implantation and design of means or elements of the equipment should be consistent with the operatingand user modes.

! Movements must be as short and untiring as possible.

! Visibility should be at a maximum for the main elements to be monitored.

Elements to be understood

In order to respect these principles, the following points should be closely examined:! the nature and places of work of the operators (surveillance, control, loading, maintenance, etc.),

! the location of the manual work stations,

! the location of the person-machine interfaces (console, screens, etc.),

! the location of the control station(s),

! the location of the loading and unloading stations,

! the types of defective operating run modes and the localisation of possible discharging and re-stuffings,

! the number, location and types of access to the installation,

! the types of material safety protections,

! the different types of flows (parts, equipment, consumables, etc.),

! the parts-in-progress at the start and end of the line and between the machines,

! the supply and evacuation of consumables and waste,

! the sources of noise,! the means of extracting the smoke, dust and toxic substances, and salvaging pollutant products,

! pathways,

! areas for communication, meetings, etc.

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Specific recommendations for the passages

! Determine the main sites of intervention,

! Specify the reasons or conditions for passage above the conveyor belts, for all users (drivers, maintenanceprofessionals, etc.),

! Avoid differences in level.

Specific recommendations for the positioning of control stationsWhen the control time is long (several minutes):

! place the control station as close as possible to the command station,

! ensure that the operator can monitor the installation and has access to the important information on thefunctioning of the installation.

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F2 - Access to work stations and places of work

The access to the work stations or places of work are of the correct size, including for

breakdown assistance and maintenance.


EN 547-1(3)

The passage takes into account:

! the type of clothing (light or thick) and the protective equipment,

! the transport of tools, for example for maintenance or repair,

! the postures and gestures,

! the frequency and duration of the task,

! the length of passage,! the level of risk and the space for rapid movement in an emergency,

! the surrounding conditions (darkness, heat, humidity, noise, etc.).

Recommendations

The norm suggests a formula including the elements to be taken into account. As an example, the followingminimum dimensions respect the principles of the norm for:

! a tall man in the 95th

centile(see sheet no. 38),

! the wearing of ordinary work clothes,

! a straight posture,

! an open space for the movement of the body.

Minimum width of access in mm

Frequent access + people passing 800

Frequent access 715

Secondary access (breakdown, maintenance) 615

Rare access (passage in profile) 545

Minimum height of access in mm

Passage for moving upright 2 070

The implantation diagrams should integrate as soon as possible:

! the safety distances in relation to moving elements,

! the types of protection (height, sizes of mesh),

! the passages of ground conveyor belts,

! the passages of aerial conveyor belts,

! aerial walkways,

! the passages of cables and piping.

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F3 - Isolated work station

There is no isolated operator due to the implantation and/or organisation of the work.

Normative specificationsThere are no norms dealing with this situation, but there is a documentary note from the National Institute ofResearch and Safety in France.

"a task or a work station is to be considered as isolated when the operator is out of sight or hearing of theothers, in most cases for periods of more than one hour. However, for work where the risks could not beeliminated, the notion of an isolated work station can be understood for periods of only a few minutes." (nd2052-167-97, 'cahier des notes documentaires no. 167', 2nd quarter 1997 of the INRS)

Recommendations

The situation of isolation should be considered from three angles:

! the mental load work and of anxiety which may occur as a result of not being able to talk or not being able to

confront work situations (doubts with regard to quality, for example) with other colleagues,! insertion in the work group,

! safety, in particular the risk of not being able to provide assist device quickly.

For each situation of operator isolation, it is recommended that the following procedure be implemented:

! Undertake a study of the problems and risks.

! Take compensatory organisational measures (rotation of operators, etc.).

! Provide all useful information concerning the correct work procedures.

! Provide the operator with the appropriate equipment

! Ensure that the person can be given rapid assist device in the event of manifest residual risks.

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F4 - Signalling measures and service components

The important signalling measures are placed in the operator's field of vision.The positioning of service components allows movements to be optimised and risktaking or accidental manoeuvres to be avoided.


EN 894-1( 4.3.3)

It is recommended that the body movements necessary to activate the service components are not a source ofinterference for the operator.For efficient running, the different service components must be separated by an optimum distance, as too greata distance can necessitate pointless movements while too short a distance increases the risk of accidentalmanoeuvres.In order to determine the optimum distance, it is essential that the specific characteristics of both each servicecomponent and the general context of the use be taken into account.

Recommendations

! Describe as early as possible the future activity of the operator.

! Position the command system so that the operator has a view of the entire installation from this station.

! Orient the consoles so that the operator can see the component he is controlling.

! Design the part conveyor belts using swivelling parts or lifts to facilitate access to the consoles.

! Provide for sitting stations as soon as an activity takes place for several minutes without movement.

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F5 - Functional dimensions of equipment

The functional dimensions of the equipment integrate the differences in size andcorpulence of the operators.


EN 614-1( 4.1.1)

The design of the work equipment should respect the following principles:

! the height of use or other functional dimensions of the equipment should be adapted to the operator and thetype of work effected, for example by being adjustable,

! sufficient space should be provided for all parts of the body so as to allow the movements necessary to carryout the task and to facilitate access and changes in the posture.

Recommendations

The design of the work stations is a compromise resulting from:

! an examination of the problems encountered by tall and short people,

! the choice of the least disadvantageous dimensions: with the same back posture, the lower position mustoften be favoured.

When the compromise is difficult to determine, the possibility will be examined of integrating dimensionaladjustments on the station which are easy to implement (quick and little effort), ensuring that the installationsare not rendered more complex and the reliability is not affected.

For the dimensions of the equipment, three pieces of anthropometric data must be systematically taken intoaccount:

! the height of the eyes, which will determine the upper height for taking visual information,

! the height of the shoulders, which will determine the upper limit for access to a technical device or for liftingan object,

! the height of the hands (with arms at side of body), which will determine the lower limit for access to atechnical device or for lifting an object.

See the French norm NF X 35-104concerning dimensions for the design of work surfaces and volumes.

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F6 - Protective equipment

The design of means includes material protection measures and individual protectiveequipment.


EN 614-1( 4.1.1)

No specification

Recommendations

1. Material measures

Norm EN 294sets the safety distances to prevent dangerous zones from being reached by the upper limbs.In order to respect the ergonomic recommendations, the best compromise possible is required between safety

and visibility of the installations. For the protective grilles, this implies:

! choosing the largest possible authorised mesh,

! maintaining good visibility above the protection, respecting the heights specified in the norms,

! having a dark matt colour to facilitate visibility through the mesh,

! choosing square or rectangular meshing (left-hand photo) without rippled wire,

! providing either a plinth to avoid entry of dirt, or a gap of 200 to 250 mmbetween the ground and theprotection to facilitate cleaning (using a brush).

2. Individual protective equipment

Adopt the following procedure to limit the risks and adapt the means of protection to the work activity:

! reduce the risks at source through the design of the product and the design of the product-process,! in the event of risk, favour collective protective measures,

! if a risk remains, adapt the individual protection to the activity, avoiding the operator having to put on andtake off the protections very frequently.

! specify the type of individual protection marked on the safety sheet at the work station.

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F7 - Documentation

The documentation on the use and maintenance of the equipment is available andunderstandable to the users.


EN 614-1( 5.2.3)

The documentation should include the operator information and the method of using the equipmentergonomically.

Recommendations

The preparation of the documentation should occur in four stages:

! the definition of the functioning modes,

! the associated definition of the user modes, which can lead to the adaptation of certain functioning modes,

! the preparation of an operator manual or notebook,

! the preparation of safety sheets (precautions to be taken, wearing of individual protections, etc.) andinstructions for use of chemical products or dangerous substances.

The preparation of the manual or notebook should be effected by:

! referring to the supplier documentation,

! involving the future operators,

! by capitalising the know-how transmitted within the framework of supplier training courses,

! by differentiating the information for learning periods (operating procedures, etc.) from the information forexperienced operators (resolution of complex problems, etc.).

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F8 - Noise

The noise levels are below the following values:75 dB(A) for equipment in the assembly sectors,

80 dB(A) for equipment in the other sectors.The peak level is below 130 dB (C).


EN 614-1( 4.4.1)

The noise emissions and vibrations produced while the work equipment if functioning should be reduced to theminimum in order to avoid health risks and to ensure the comfort of the operators.

The design methods should allow the emissions to be controlled at source to an extent that the final emissionvalues are low compared to the other machines of the same type.

EB75.81.325

Apart from particular specifications during the call to tender, the limits not to be exceeded at the station and atany point located within one metre of the equipment are as follows:

Workshops LpAeqT Lpc

Pressing, forge, foundry, stamping, boilerworks.

Machining, bodywork, framing, painting, plastics.

80 dB(A) 130 dB(C)

Fitting, assembly, upholstery, body trimming. 75 dB(A)

The number of measuring points is equal to the perimeter of the work equipment (in metres) divided by 5, with aminimum of 4measuring points.

Measurements are taken 1metre from the work equipment and at a height of 1.60 m.

The clearly identified work stations are also measured at the height of the operators' ears.

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F9 - Lighting

Lighting is adapted to the task to be effected. It is at a level of between 500 lux forwork on average-sized parts and 750 lux for work on small parts.

There is no dazzling.The rendering of the colours is satisfactory.


EN 614-1( 4.4.3)

When the analysis of the task emphasises insufficient ambient light, integrated lighting should be provided, forexample for adjustments to be effected.

This lighting should be designed so that the operator does not have to adopt an uncomfortable posture.

When the lighting must be adjusted, the means of adjustment must be situated in an appropriate location andshould avoid placing the operator in danger.

Particular attention should be paid to the following points:

! avoid any twinkling of the lights,! avoid all dazzling lighting,

! avoid the projection of shadows which are likely to create a certain confusion,

! avoid stroboscopic effects,

! lighting contrasts should be sufficient for the task to be effected,

! the rendering of the colours must be maintained.

EN 1837( 4.2 to 4.5)

The lighting required depends on the visual task and must be sufficiently bright and uniform to allow sure andcomfortable visibility of the details of the visual task.

As a general rule, an average maintained lighting of at least 500 luxmust be accompanied by a minimumuniformity (Emin/Eaverage) of 0.7in the work zone and 0.3for the immediate surroundings of the task.

The integrated lighting system must avoid dazzling... and be designed and adjusted to avoid interferingshadows...

The properties of the rendering of the colours and the visible colour of the lights must be chosen to allow gooddistinction of the colours of the visual task and the comfort of the user.

Recommendations

The following elements are taken from the norm NF X 35-103and the recommendations of the LightingAssociation.

Average recommended lighting levels

Applications lux

Entrances, yards, alleys

Covered traffic lanes

Docks and quays

30

50

75

Corridors, stairwells

Warehouses

100 to 300

125 to 150

Offices, typing areas

Drawing rooms

425 to 500

1000

Machines-tools, workbenches, welding

Work on average-sized parts

Work on small parts

Fitting of small parts

250 to 300

425 to 500

625 to 750

625 to 750

Very intricate work or very small parts 1250 to 2000

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Temperature of colour and colour rendering index

Applications Lights Temperature of colourin Kelvins (K)

Colour renderingindex (IRC)

Regular workshops

Administrative offices

White rooms

Fluorescent tubes

2700 to 6500 !80

Industrial halls and premisesof a height of more than 8 m

Iodides

Mercury vapour

3700 to 6100

3300 to 4300

65 to 93

33 to 60

Very high premises,warehousing, hangars

High-pressuresodium

2000 to 2500 25 to 80

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F10 - Thermal atmospheres

In the periods when heating is used and for a regular industrial activity, thetemperature lies between 16 and 22, with relative humidity between 30 and 70 %.

There are no draughts, verified by an air speed which is, in principle, less than 0.25m/s.

Warning, this sheet does not deal with conditions of extreme heat at work (thermal treatment, foundries, etc.).


EN 614-1( 4.4.2)

The thermal emissions produced while the work equipment is functioning should be reduced to the minimum bymeans of the design methods in order to avoid health risks and to ensure the comfort of the operators.


! the physical load of the operator,! the thermal properties of the required clothing,

! the foreseeable thermal load for the operator,

! the temperature of the tangible areas (see EN 563)

ISO 7730Thermal comfort is defined as the satisfaction expressed with regard to the thermal atmosphere.

Dissatisfaction can be caused by:

! tepid or cool discomfort for the body, etc.

! a draught...

!

abnormally large differences in temperature between the head and the ankles.

It is impossible to stipulate a thermal atmosphere which satisfies everyone. However, it is possible to stipulateatmospheres which are acceptable to a percentage of the occupants.

According to appendix C of the norm, and in order to satisfy at least 93%of the occupants, the operatingtemperature should correspond to the following values for regular industrial activity (metabolism of 116 W/m

2).

Operating temperature ClothingOther characteristics ofthermal atmosphere

16 to 19Underwear, shirt, trousers, socks, shoes.

Relative humidity of 50%

19 to 22Boxer shorts, short-sleeved shirt,lightweight trousers, thin socks, shoes. Air speed of 0.15m/s

According to appendix B of the norm, the following values are given for the metabolism per profession:

- intricate mechanics 70 to 110 W/m2.

- welding and turning 75 to 125 W/m2.

The operating temperature can be calculated, with sufficient approximation, as the average value of the airtemperature and the average radiation temperature.

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F11 - Cleaning work stations

If dangerous materials are used, appropriate measures are available to avoid theoperators being exposed to health risks.


EN 614-1( 4.4.4)The work equipment must be designed so that any dangerous material and any dangerous radiation presentduring use are indicated and dealt with via appropriate measures in order to avoid the operator being exposedto health risks.

Recommendations

The use of dangerous substances and products is limited to those that are strictly necessary, favouring the leastdangerous, and requires permission for use. The suppliers, in particular, are bound to communicate to thecompany the composition of the products so as to adapt the protective measures accordingly.

The products used:

! are labelled according to the regulatory criteria,

! are packaged, stored, handled, used and eliminated in a way which reduces the risks,

! are provided with user instructions indicating the rules of use to be respected and the obligatory individualprotections to be worn.

Any emission of dust, steam or smoke must be collected at source, according to the following principles:

! provide maximum cover of the zone where the pollutants are produced,

! collect them as close to the emission zone as possible,! position the extraction device so that the operator is not situated between it and the pollution source,

! use the natural movements of the pollutants,

! induce a sufficient air speed,

! distribute the air speeds uniformly at the level of the collection zone,

! balance the air outlets by corresponding air inlets,

! avoid draughts and feelings of thermal discomfort,

! eject the polluted air outside the clean air inlet zones.

Protection against radiation is dealt with within the framework of the safety conformity report.

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F12 - Operating installations - Relevance of information

" The signalling devices provide clear and unequivocal information.

" The information important to the efficiency of the process, safety, security and thereliability of the system are obtained via different means.

" The control system is adapted to the learning and individualisation possibilities:a possible adjustment of the information needs,a possible choice between simplified and detailed procedures for the access toinformation or parameter control (e.g. adaptive menu).


EN 614-1( 4.3.1)

The signalling means should be designed, chosen and arranged to be compatible with the characteristics ofhuman perception and with the task to be effected.


! the signalling means should be designed so as to be understood clearly and unequivocally; this isparticularly important for emergency displays and signs,

! in order to avoid an excess of information, the number and type of displays and signs should be limited tothe minimum required for the correct execution of the task,

! the presentation of unnecessary information should be avoided,

! the signalling means should be positioned in such a way as to favour a sure, clear and rapid orientation andrecognition.

EN 894-1( 4.3.1)In certain situations, the efficiency and security of a system depend on its ability to present repeated informationto the operator. It is recommended that important information be able to be obtained from different sources.

EN 894-1( 4.6)

The system should be sufficiently flexible to be adapted to the different individual needs, general physiologicaland psychological capacities and learning capacities, as well as cultural differences.

The operator should, if possible, be able to modulate the speed of interaction. An experienced operator shouldbe capable of structuring the feedback information for it to correspond to his level of competencies. Inversely, itis recommended that an inexperienced operator be able to adjust the level of the feedback information to hisneeds.

In a complex system, it is desirable that the operator have a choice of an availability of global or detailedinformation concerning the system.

RecommendationsFive categories of informationcan be contained in a user assist device system:

! operating aids (changing tools, restoration of the cycle, changes in working modes, monitoring of drifts,information on induced stoppages),

! production management aids (frequent samples, quantifications),

! malfunction detection aids (exceeding tack time, part faults, loading or unloading faults, breakdowns),

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! breakdown diagnostic aids,

! monitoring performance indicators (reliability, quality).

For each category of information, it must be ensured that:

! only the information necessary to the operator is presented, that is the info that he will use to confirm orvalidate his own analyses, in particular concerning breakdowns,

! the confrontation of information from the system are confronted with information taken directly from theinstallation (visual or audible),

! the information is presented in a form corresponding to the operating process in order to reducememorisation efforts,

! understanding of the visual signals aimed at triggering an emergency intervention are facilitated by areinforcement of the signal: dimension, position, flashing, combined with audible signal,

! adaptation of the access to information is possible according to the competencies acquired.

The lampsshould be positioned at the correct height to be visible in the main areas of intervention of theoperators.

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F13 - Operating the installations - right-handed and left-handed operators

The service components can be activated by both hands, notably when the operatingmode requires the use of both hands.


EN 894-1( 4.6)

With regard to laterality, most service components can be activated using both hands. However, the servicecomponents which require precise and/or rapid operation must be able to be activated by either hand ordesigned to allow a precise and/or rapid action by the dominant hand.

Recommendations

Dominant handThe dominant hand refers to:

! the right hand for right-handers,

! the left hand for left-handers.

Precise actionIn the case of a precise and/or rapid action, the operator must be able to intervene with his dominant hand. Inparticular, it is recommended that the emergency stop button be placed in the centre of the control console in

order for it to be reached equally quickly by right-handers and left-handers.

Overcrowding of operatorsWhen two operators work side by side, the space between each station should take into account the possibleinterference resulting from the fact that the operator on the left is right-handed and the operator on the right isleft-handed.

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F14 - Operating installations - Layout of control system components

The signalling devices and command components are:" arranged in the same order, if they are used according to a fixed sequence," positioned in the control order," easily identifiable by their position in the area," easily and quickly accessible for the most frequent or for those working on the safety

of the use of the machine.


EN 894-1 ( 4.1.3 )

This type of organisation helps the operator to remember the operating sequence and reduces both theresponse times and the risks of errors.

If the signalling measures and service components are not used in a fixed sequence, their grouping should bedetermined according to the following aspects:

! the importance for the safety of the machine,

! the frequency of use in the regular functioning of the machine,

! combined use of elements in a sub-sequence.

EN 894-1 ( 4.2.6 )

If the sequences of activities require the signalling measure to be read in a pre-determined order or if they arelinked to machines which have a numbered order, the signalling measures should be placed in the same order

and should read from left to right or from top to bottom of the panel.

Recommendations

! To simplify identification and minimise the risks of incorrect manoeuvres, the luminous buttons on thecommand console should be grouped into sub-groups taking into account the following criteria: types ofoperation, functions, sequences of use or manoeuvre procedures, frequencies of use, modelling theimplantation of the machine.

! If the luminous buttons are grouped together byoperation type and there is a sequence between theseoperations, it is recommended that the controls andsignals relating to this sequence be arranged in theorder (from left to right or top to bottom) correspondingto the process of the sequence.

1 2 3 1

2

3

! The indication of the type of control button or warning light (cycle start, cycle restoration, etc.) should beplaced above each one in order to reduce the risks of operating errors.

! In general, the emergency stop punch button (surrounded by a yellow ring) should be placed so as to behighly accessible for the operator and for third parties, preferably on the lower section of the commandconsole or table. It should be easy to identify and use thanks to its colour (red) and its size.

! Only the components necessary to the activity of the operator need to stand out from the installation.

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F15 - Operating installations -Colours of signalling and control measures

The signalling and control system measures are easy to identify by colour code.


EN 894-2( 4.2.6 )No specification

EN 61310-1( 5.2)

The colours should be chosen according to the information to be provided. The colours of the indicators and theservice components should conform to the following table:

Meaning

Colour Safety of personnel Conditions of themachine or procedure

State of the equipment

Red Danger / prohibited Emergency

Yellow Warning Abnormal No meaning

Green Safe Normal General

Blue Obligatory

White, grey, black No particular meaning allocated

Recommendations

! The normEN 60073uses the data from the previous table and applies them to the design of warning lightsand push buttons:

COLOUR FUNCTIONNON-LUMINOUSPUSH BUTTONS

FUNCTIONLUMINOUS

PUSH BUTTONS

FUNCTIONLUMINOUS

WARNING LIGHTS

RED !Stop!Out of order!Switched off

!Stop!Resetting

Alarm signalling faults orabnormal conditions requiringthe intervention of the operator.

YELLOW !Start servicing!Execution

!Switch on!Start

!Warning/caution!Request for intervention!Component not in position

GREEN !Start!Install!Switch on!Preparation

!Start!Authorisation to start cycle

!Machine ready

BLUE Any function not colour-specific

BLACK !Start!Install!Execution

WHITECOLOURLE

SS

!Switch on circuit!Start function

!Circuit switched on!Permanent condition of normal

functioning

! The emergency stop measures should be in RED.

! The number of colours should be limited (5for static images, only 3for dynamic interfaces) to makedifferentiation by the operators rapid and reliable.

! Each colour should only represent a single data category.Changes in state should be identified by specific warning lights.

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F16 - Operating installations - Respect of conventions

The common conventions or the stereotypes are respected.


EN 894-1 ( 4.4 )

The stereotypes of the population and other expectations of users with regard to the functioning mode of theman/machine interface are important parameters in determining how an operator will use a particular servicecomponent or signalling measure.

In a situation of stress, we might expect the operators to return to the stereotypes of their population, even ifthey have been trained to act to the contrary.

The function, movement and position of the command and signalling means should correspond to the

expectations of the operator, whether they are the result of his professional experience or his training.

EN 60447

The correlation between the direction of the manual action on a manoeuvre component and the direction of thefinal effect obtained by this action is especially important with regard to security when a false manoeuvre cancause damage or when frequent or rapid actions are necessary.

The following tables, drawn up according to norm EN 60447, list the actions and their expected effects.

Nature of themanoeuvre

component

Direction of the action Expected effect of themovement

Steering wheel,handle,

button, etc.

clockwise

anticlockwise

Handle,

lever, etc.

upwards

with conventional downwards

rectilinear to the right

movement to the left

moving away from the operator

moving towards the operator

x

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Type of the set of components Type of theaction

Point of application of the action

Set of

handles,push buttons

One above the

other

Pressure,

shafts, pullknobs, etc.withantagonisticeffects

One next to theother

tractions, etc.

Type of the set of components Type of theaction

Classification of the action

Terminal with display screenwith XY manipulator

Movement andactivation

Keyboard Hitting keys Direction of the action and point of application:

non-classified, as far as possible

Sensitive surface Touch apply the previous rules.

Action on thelower

component

Action on theuppercomponent

Action onthe left-handcomponent

Action on theright-handcomponent

x

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F17 - Operating installations - Choice of display measures

The display measures are adapted to the types of observation to be effected:

"

digital display for a measured value," analogue display to mark a tendency in a tolerance space,

" display with memory to monitor changes.


EN 894-2( 4.2.5)

When a signalling measure is used, three basic types of observation are realised and are often demandedalmost simultaneously. These types of observation are:

! Reading a measured value

Reading a measured value (quantitative observation) is a task of perception in which an indicated value isnoted. To this end, the speed of modifying the indication is sufficiently low to allow a precise observation. Thefigures of the digital display should not vary more than twice per second.

! Moving readingA moving reading is a task during which a verification is made by a quick glance in order to see if the valueindicated corresponds to a pre-determined value, or if the value falls within a fixed tolerance range.

! Monitoring the modifications of a valueMonitoring the modifications of values measured constitutes a task during which the observer notes thedirection and speed of modification of the values measured. This type of observation is characteristic of processoperating tasks.

Recommendations

The choice of the signalling measures is effected according to the task:

! Digital display to effect the precise results:

! Analogue display with no memory to mark the trends or adjust a parameter:

! Analogue display with memory to monitor the changes, favour the diagnostics and the forecasts:

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F18 - Operating installations - Analogue display

In the case of analogue displays:

" the pointers occupy the same angular position to indicate the normal state,

" the correct zones are marked in green and the incorrect zones in red.


EN 894-2( 4.2.6)

An analogue display is a display in which the status information is represented by a length, an angle or anotherphysical measure. In the case of visual displays, the information can be represented by the movement of apointer, the length of a bar chart or a similar visual measure. In the case of audible signalling measures, theinformation can be represented as a function of pitch or sound intensity level. In the case of tactile signallingmeasures, the information can be represented by the vibration (frequency or amplitude) or the movement of thedisplay.

To facilitate the detection of abnormal conditions to the maximum, thesignalling measures should be placed so that all the pointers are inthe same angular position when they indicate the normal status (seefigure).

The homogenous grouping of pointer displays improves the detection of a discrepancy.

Recommendations

! Adapt the scales so that the grouped analogue displays indicate their normal status by the same position.

! Use a colour (green) to indicate the zones where the measurement is considered normal and another colour(red) for those where the measurement is abnormal.

FAULT

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F19 - Operating installations - Choice of signals

The signals relating to safety are designed so that their meaning is obvious, clear and

unambiguous to the user.


EN 61310-1( 4.1)

Active signals should be used to signal a risk (dangerous phenomenon) and to request that the personnel takeparticular measures.

Passive signals should be used as a warning in the event of permanent probability of risk or to provideinformation concerning the position, for example emergency exits or emergency stop measures.

If possible, visual signals should be used.

Additional means to visual signals, such as audible or tactile signals, should be chosen and used in caseswhere:

! the operator has a visual deficiency (blindness, colour blindness),

! the operator needs to look elsewhere when working or activating the controls,

! the people exposed are out of sight of the operator,

! the people exposed cannot see the warning signals.

The table below, extracted from the norm, provides some examples of signals:

Signal Visual Audible Tactile

Active Start/stopor change of:

! colour! brightness

! contrast

! saturationFlashingChange of position

Start/stopor change of:

! frequency! intensity (sound level)Type of sound

VibrationChange of position

Click/snapPositioning with positive reaction

Passive Security signalAdditional signalMarkingShape, colour.

Silence ShapeRoughness of the surfaceReliefRelative position

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F20 - Loading and unloading parts - Tempo of the operator

" The tempo of the operator is not strictly linked to the cycle of an automatic or semi-automaticmachine.

" Regulation is at level 3 (Renaultergonomic analysis methodreference). The result isevaluated according to the objectives of the project.


EN 614-1( 4.5)

The independence of the operator can be ensured by stock buffers, supply devices, robots, etc.

Recommendations

! For continual execution of tasks of loading and unloading, the dependence can be regulated:! by validation of the cycle start by the operator,! or by creating parts-in-progress.

The "regulation" criterion of the Renault ergonomic analysis method allows an evaluation of the constraint ona scale with fivelevels. The regulation is acceptable for levels !3 (see evaluation sheet in appendix 1).

! If it is a case of multitasking, parts-in-progress must be created at the line entry and/or exit, the quantity of

which is a function of:! the longest activity sequence, which cannot be interrupted (control, changing tools, etc.),! rest times, if it is desired that the installation work during the break.

The Renault ergonomic analysis method does not apply to this type of situation.

! Bringing supply and evacuation closer together, for example by designing a U-shaped line, offers severaladvantages:

! the reduction of movements of operators,! greater flexibility of organisation and exploitation,! a reduction in conveyors belts when the pallets are returned,! a gain for the supply chain.

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F21 - Loading and unloading parts - Postures

" There are no uncomfortable postures, significant twisting or flexing of the body,movements likely to cause illnesses or bodily injuries, including in defective modes.Support for the body is appropriate in order to avoid off-balance postures.

" The posture constraint is at level 3 (Renaultergonomic analysis methodreference).The result is evaluated according to the objectives of the project.


EN 614-1( 4.1.2 )


! uncomfortable postures, for example twisting and flexing the body, as well as prolonged activities causingbodily fatigue should be avoided,

! an appropriate posture and support for the body is to be ensured. These supports should be of a size and

positioned so as to avoid off-balance postures.

Recommendations

The "posture" criterion of the Renault ergonomic analysis method allows and evaluation of the constraint on ascale with five levels. The posture is acceptable for levels !3indicated in the extract from the evaluation sheet

below.

3Hands betweenthe heart and

the shoulder2

3 4

Hands at

head height

Elbow atshoulderheight

Armsoutstretchedwith no support

Slight twisting

Leaning

30 to 45

Leaning

$ 45

Leaningto the side

Considerabletwisting

Leaning30 to 45

Risk of osteo-articularparthologies(including lumbar) 54

Leaningconsiderablyto the side

Twisting ofalmost 90

Flexing +

and Rotationof back

Leaning

$ 45

Leaning

backwards

Crouchingorkneeling

POSITION OF THE UPPER LIMBS < 20% tcy 20% to > 30% tcy

JOINTS USED30% tcy

or or or

< 50 f/h 50 100 f/h > 100 f/h

POSTURE

FRONTAL

WITHOUT

SUPPORTLATERAL

POSITION OF THE BACK

Prolonged hyperextension

or hyperflexingof wrist

Intense repeatedtightening orpressure of fingers

Repeated maximumsupination movements

Global level of station:maximum level observed

weighted by the sum of the

frequencies or the holding times

FRONTAL

WITH SUPPORT

POSITION OF

THE HANDS AND

ARMS

Leaning

slightly,10 to 30

Leaningslightly to

the side 3Hands betweenthe heart and

the shoulder2

3 4

Hands at

head height

Elbow atshoulderheight

Armsoutstretchedwith no support

Slight twisting

Leaning

30 to 45

Leaning

$ 45

Leaningto the side

Considerabletwisting

Leaning30 to 45

Risk of osteo-articularparthologies(including lumbar) 54

Leaningconsiderablyto the side

Twisting ofalmost 90

Flexing +

and Rotationof back

Leaning

$ 45

Leaning

backwards

Crouchingorkneeling

POSITION OF THE UPPER LIMBS < 20% tcy 20% to > 30% tcy

JOINTS USED30% tcy

or or or

< 50 f/h 50 100 f/h > 100 f/h

POSTUREPOSTURE

FRONTAL

WITHOUT

SUPPORTLATERAL

POSITION OF THE BACK

Prolonged hyperextension

or hyperflexingof wrist

Intense repeatedtightening orpressure of fingers

Repeated maximumsupination movements

Global level of station:maximum level observed

weighted by the sum of the

frequencies or the holding times

FRONTAL

WITH SUPPORT

POSITION OF

THE HANDS AND

ARMS

Leaning

slightly,10 to 30

Leaningslightly to

the side

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F22 - Loading and unloading parts - Gripping parts

It is possible to ensure good lifting and a good balance of the parts.

Lifting and positioning are effected with no risk of parts being dropped or hands being

jammed, including in defective modes.


EN 614-1( 4.1.4)

The gripping components should be studied, chosen and arranged so that the application of the physical effortnecessary is as low as possible without the application of these principles having negative effects on health andsafety.

Positioning should be effected with no risk of parts being dropped or hands being jammed.

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F23 - Loading and unloading parts - Handling efforts

The physical efforts during the execution of the task are limited to acceptable levels,including in defective modes.

The effort constraint is at level 3 (Renaultergonomic analysis methodreference).The result is evaluated according to the objectives of the project.


EN 614-1( 4.1.4 )

With regard to handling, these levels depend on the weight, shape, size, mass distributions and the position ofthe objects.

Recommendations

The "effort" criterion of the Renault ergonomic analysis method allows and evaluation of the constraint on ascale with five levels. The effort is acceptable for levels !3indicated in the extract from the evaluation sheet

below.

In any case, the use of an assist device should be easy and should not induce a longer handling time of theparts.

EFFORTFrequency

of

repetitionper hour

0,3 % 1,5

1# 5% # 5

1,5 % 2,5 2,5 % 4 4 % 6 6 % 9 9 % 12 12 % 16 16 % 21 21 % 28$ 28

Weights or efforts(Kg ou DaN)

21 to# 30%

6 to# 10%11 to

# 20%

31 to# 40%41 to

# 60%61 to

# 80%81 to

# 90%91 to100%

6 to# 3031 to# 6061 to# 9091 to# 140141 to# 220221 to# 330331 to

# 500$ 500

1 1

11

1

1

2 2

22

22

2

2

3 3 3

3

3

3

3

3

33

33

3

3

3

3

3

3 3

3 3

2

EFFORTFrequency

of

repetitionper hour

0,3 % 1,5

1# 5% # 5

1,5 % 2,5 2,5 % 4 4 % 6 6 % 9 9 % 12 12 % 16 16 % 21 21 % 28$ 28

Weights or efforts(Kg ou DaN)

21 to# 30%

6 to# 10%11 to

# 20%

31 to# 40%41 to

# 60%61 to

# 80%81 to

# 90%91 to100%

6 to# 3031 to# 6061 to# 9091 to# 140141 to# 220221 to# 330331 to

# 500$ 500

1 1

11

1

1

2 2

22

22

2

2

3 3 3

3

3

3

3

3

33

33

3

3

3

3

3

3 3

3 3

2

!

!!!!

""!

"!!!! "

""

#

"

$$

$$

$$

$$

#

##

#

Recommendations for handling aids

Assist device required for people with restrictionon carrying heavy loads

Assist device recommended, with possibility of:either carrying several parts at the same time,or using assistance for functions otherthan handling.Assist device obligatory

Automation or assistance allowing several partsto be carried at the same time,or implementation of organisational locks

"

!

$

#

#

"

CONDITIONS:if one of the following conditions applies,multiply the real weight by 2 in the grid opposite.

- Turning the load with risk of damage.

- Lifting and holding load with arms spread or outstretched- Delicate positioning or hanging with prolonged balancing in

one hand only- Lifting pieces with finger ends and/or strong pressure of fingers

or wrist- Non-rigid load or load without clear hold.- Load lifted in sitting position- Effort directed in abduction (arms spread outwards)

Holdingtime

(% of tacktime)

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F24 - Controlling the parts - Information and means

All information (control plans, documentation, etc.) and all means necessary for theexecution of the task are made available to the operator.


EN 614-1( 4.2)

No specification

Recommendations

! The control plan should specify as early as possible what the operator needs in terms of information and

means to validate (or not) the quality of a part by reducing the differences in interpretation to a minimum.

! The needs are determined according to the feedback necessary for the operation of the installations. Inparticular, we distinguish:

! the line-side control which allows a rapid return of partial information for the operator, for example afterchanging tools or equipment,

! more exhaustive controls, such as 3D controls, for less frequent information feedback.

! The documentation at the station should be clear and understandable.

! The lighting level should be strengthened above the control station and adapted to the intricacy of the faultsto be detected. For example:

! 750lux for work on small parts,! 1500to 2000lux for work on very intricate or very small parts.

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F25 - Controlling the parts - Postures, gripping, efforts

There are no uncomfortable postures, significant twisting or flexing of the body,movements likely to cause illnesses or bodily injuries. Support for the body isappropriate in order to avoid off-balance postures.

! It is possible to ensure good lifting and a good balance of the objects.

! Lifting and positioning are effected with no risk of the objects being dropped or handsbeing jammed.

! The physical efforts made while the task is being effected are limited to acceptablelevels. There is no prolonged static muscular tension.


EN 614-1( 4.1.2 )The design of the work equipment should respect the following principles:

! uncomfortable postures, for example twisting and flexing the body, as well as prolonged activities causingbodily fatigue should be avoided,

! an appropriate posture and support for the body is to be ensured. These supports should be of a size andpositioned so as to avoid off-balance postures.

EN 614-1( 4.1.4)

Any prolonged static muscular tension (such as that caused by holding the hands or arms in a raised position)should be avoided.

Recommendations

! The postures adopted for lifting, replacing and withdrawing the parts are determined by:

! the height of the work surface, excl. control fitting,! the height of control fitting,! the modalities of inserting the part in the fitting.

! The risks or difficulties are determined by:

! the characteristics of the parts (slippery, hot, etc.),! the weight of the parts,!

the gripping conditions,! the postures adopted for lifting replacing and withdrawing the parts,! the postures adopted for controlling the parts.

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! For parts weighing 9 kgor more, the following should be provided:

from 9 to

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F26 - Changing tools and equipment - Information

All information necessary to the execution of the task are made available to the operatorso as not to impose unacceptable demands on him in terms of speed of intervention


EN 614-1( 4)

No specification

Recommendations

! Adequate information measures allow the status of the tools to be controlled and the reliability of thechanges to be programmed and guaranteed.

! For each tool, the operators must know:

! the number of cycles effected since the last change,! the theoretical frequency of change,! the real previous, or even the 2 previous, frequency(ies),! the warning threshold.

! This information should allow the operators to be responsible for decision-making in order to combineseveral tool changes, thus limiting the stoppage times of the machines.

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F27 - Changing tools and equipment - Postures, gripping, efforts

" There are no uncomfortable postures, significant twisting or flexing of the body,movements likely to cause illnesses or bodily injuries.

" It is possible to ensure good balance and a good grip of objects held in the hand." Lifting and positioning are effected with no risk of the objects being dropped or hands

being jammed.

" The physical efforts made while the task is being effected are limited to acceptablelevels. There is no prolonged muscular tension.

" The forces are of a low level for movements requiring a high level of precision.

" The combination of posture and the weight of the tools or equipment does notdemonstrate dorso-lumbar risks.


EN 614-1( 4.1.2)

! Accessories should be provided for operations requiring a high level of precision (winches, support bars,stops, etc.). The work area should be sufficiently large to accommodate such accessories.

! Movements of rotation requiring the application of large forces should be avoided; this is particularly true forthe extreme positions of the hand / arm joints.

! Any prolonged static muscular tension (such as that caused by holding the hands or arms in a raisedposition) should be avoided. The weight of the equipment held in the hand can be an important cause ofmuscular fatigue when prolonged durations of use are required and, consequently, its effect should bereduced, for example by supporting the said equipment using a suspension system.

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Recommendations

! Work surfaces and volumes

The zones reached depend on the weight of the toolsand equipment and should fall within the limits opposite.

These limits are understood:! with a maximum twisting of 15,

! without holding parts in extreme positions.

In particular, the following should be avoided:

! postures leaning more than 45,

! twisting more than 30,

! arms above shoulder height.

The positions in lower parts (height of 500to 600mm)are acceptable insofar as the operator can bend his legs.

Always provide for a hollow for the feet, thus allowing theoperator to:

! move in as close as possible,! to be supported on his lower limbs.

For weights greater than 16 kg, an assist device shouldbe implemented according to the recommendationsindicated on sheet F25 - Controlling parts - Postures,gripping, efforts.

! Gripping

The following points are recommended:

! good design for gripping points in order to avoid, inparticular, uncomfortable positions of the hand and

forearm, as well as the risk of jamming whenchanging tools.

! elimination of obstacles interfering with lifting thetools or the risks of cutting or collisions,

! use of adapted aids or mechanical measures toblock parts, suspension systems with stabilisers forheavy tools.

! wearing of gloves, which alter sensitivity, be takeninto account.

< limit of the position

of lower limbs

1700

1100

500

1500

12 16 Kg

9

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F28 - Changing tools and equipment - Openings and access holes

The sizes of access holes:

! respect the normative recommendations,! take into account the task to be effected and the means used.


EN 547-1 and EN 547-2

These norms provide the dimensions of the openings and passages for each part of the body which is to accessvia these holes: upper body, arm, hands, etc.

Recommendations

The width of the openings for the passage of elbows and shoulder should be:

!545 mmfor a man in the 95th

centile

!plus the space necessary to avoid collisions,

! i.e. a minimum width of 745 mm.

A greater width should be allowed for if considerable movement of the upper limbs is necessary, notably withelbows spread.

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F29 - Maintenance or settings - Executing a function

Executing a function is possible from different points when there are certain

imperatives: speed, precision, safety or health. Adequate means are implemented to allow efficient information feedback concerning

the adjustments or fine-tuning effected (e.g. position sensors, mobile console, video,etc.)


EN 894-1( 4.3.1)

Provide the necessary measures for additional service components when superfluousness can improve securityas a whole.Certain characteristics of the system sometimes require that the execution of a given function be possible from

different points, so that imperatives of speed, precision, safety and health may be ensured.

Recommendations

The mobile command console allows skilled personnel to enter the installation, effecting adjustment operationsas close as possible to the installation, without relying on the central console.In this case, the command of movements must be effected:

' with hands occupied and sustained action,

' slowly and with reduced effort.

Using this console cancels the functions of the main console.

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F30 - Maintenance or settings - Spaces, openings and access holes

The spaces and access allow significant twisting and flexing of the body or off-balance positions to be avoided.

The spaces and access holes take into account:size and corpulence,

postures and gestures,

the position of the hole in relation to the person,

the frequency and duration of the task,

the transport of tools,

the length of passage,

the types of protective clothing and equipment,

the level of risk and the space for rapid movement in an emergency,

the surrounding conditions (darkness, heat, humidity, noise, ventilation).


EN 547-1 and EN 547-2

These norms provide the dimensions of the openings and passages for each part of the body which is to accessvia these holes: upper body, arm, hands, etc.

Recommendations

! The adjustment, lubrication and maintenance components (distributor, electrical box, detector, etc.) shouldbe accessible in total security and, when possible, from the ground and outside dangerous zones. If this is

not possible, means of access and intervention must be provided for (platform, stairs, etc.).! Provide platforms for access in total security, as in the third photo.

! Provide assist devices for carrying components when they are heavier than 16 kg and the postures are pooror off-balance.

! After the detailed study phase, the following should be provided for:

! the conditions of accessibility of repair material,! lifting means integrated into the machines,! connections to energy sources (electric, pneumatic, etc.),! specific equipment for the means,! walkways limiting movements and reducing changes in level as far as possible.

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F31 - Maintenance or settings - Efforts

The physical efforts made while the task is being effected are limited to acceptable

levels. There is no prolonged muscular tension.The forces are of a low level for movements requiring a high level of precision.


EN 614-1( 4.1.4)

The constraint imposed by the work equipment on the physical strength of the operator while working should belimited to acceptable levels. With regard to handling, these levels depend on the weight, shape, size, weightdistribution and position of the objects, the duration and frequency of the application of effort, the posture of theoperator (sitting or standing station) and the trajectory of his movements, the work rules and methods applied

and the specific characteristics of the forecast population of operators (for example, the sex, age, health,physical characteristics and training of the operator).


! When the physical effort to be applied cannot be exercised by muscle groups capable of responding to theforce requirements, mechanical assistants should be provided for.

! Any prolonged static muscular tension (such as that caused by holding the hands or arms in a raisedposition) should be avoided. The weight of the equipment held in the hand can be an important cause ofmuscular fatigue when prolonged durations of use are required and, consequently, its effect should bereduced, for example by supporting the said equipment using a suspension system.

! The application of physical effort should be reduced by using gravity or other measures.

! The service components, gripping components, handles and pedals on the work equipment should bestudied, chosen and arranged so that the application of the necessary physical effort is as small as possiblewithout the application of this principle having negative effects on health or safety.

! According to constraints of strength, size, the shape and position of service components, any unbalancing ofthe body and limbs is to be avoided. If prolonged and frequent use is necessary, the service componentsshould be used in a sitting position.

! The distribution of the weight of equipment held in the hand should ensure good balance.

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F32 - Supply and evacuation of consumables and waste - Postures and efforts

There are no uncomfortable postures, significant twisting or flexing of the body,

movements likely to cause illnesses or bodily injuries. Support for the body isappropriate in order to avoid off-balance postures.

The physical efforts made while the task is being effected are limited to acceptablelevels. There is no prolonged muscular tension.

The combination of posture and the weight of the object to be lifted does notdemonstrate dorso-lumbar risks.


EN 614-1( 4.1.4 )

Recommendations

The supply and evacuation of consumables and waste can be factors of risk and causes of loss of operatingoutput.

! After the "preparation of plans or envelope studies" phase, the following must be identified:! the consumables which will be used (cardboard, oils, etc.),! the type and quantity of the waste produced per unit of time (team, day, etc.).

! During the "detailed design or detailed study" phase, the following must be studied:

! technical solutions for the evacuation of waste in order to reduce the polluted or dirty zones within andaround the installations,

! the implementation of an assist device for weights greater than 20 kg.

! For low frequencies of changes of consumables (1 or 2times per month) and for weights below 28 kg,supply and evacuation can be planned for two operators instead of using the assist device.

! Position the elements to be lifted a minimum of 500 mmfrom the ground and provide adapted handles.

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F33 - Repetitive assembly operations - Diversity and complexity

" The work situation does not impose the implementation of too demanding informationprocessing or memorisation procedures on the operator.

" The complexity, i.e. the number of decisions to be taken in a given time, is neither tooexcessive nor too low.

" Referring to the Renault ergonomic analysis method, the decision constraint is atlevel 3 (exceptionally level 4 for a regulation 2).


ISO 10075-2( 4.2)

If the complexity is excessive for the planned population of operators, decision-making aids should be used.Too low a level of complexity should be avoided as this may cause monotony or saturation.

Recommendations

The Renault ergonomic analysis method evaluated the complexity on a scale of five levels of constraints usingthe "decision" criterion. The decision constraint should be:

! level !3for level 3regulation (sheet no. 34),

! acceptable at level 4 for regulation < 3.

!

Product diversity

! Limit the number of references to 5for the parts or components such as screws, staples, etc. If there are

more than 5 references, the choice for the operator should be reduced to a maximum of 5by means of:! an action on the product,! implementation of a help for the choice (Rack, light device, ..).

! Ensure physical identification of each reference by means of:! a visual code (digital, alphanumeric, signs, symbols, etc.) whose typography is readable and highly

discriminating,! tactile differentiation.

! Limit the time and movements between information reading on the reference and the withdrawal of the parts.

! Ensure the possibility for the operator to control the supply of the correct reference in the correct position(labels identical on bothsides, etc.).

! Create divisions tending to favour control at stations downstream, preferably in the same work shop.

! Favour the installation working at fewer than 4 batches/hour.

! Have the batch change validated by the operator.

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!Fitability

! Implement location notches.

! Ensure that the positioning is obvious, easy and does not require a high level of skill.

! Eliminate blind work if it is linked to a delicate positioning or a risk of error.

!Complexity of the task

! Limit the number of operations to 10 per cycle.

! Limit the number of tools as far as possible (screw guns, pincers, hammer, hook, paintbrush, stapler,cutter, etc.), as well as the diversity of adapters used on these tools.

! Limit, as far as possible, the cases of interpretation possible for adjustment and/or control operations.

! Ensure that the positioning of supplies and tools conforms to the operating mode.

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F34 - Repetitive assembly operations - Regulation

" The operator has the possibility of regulating the progress of the operations which he

carries out.

" Referring to the Renault ergonomic analysis method, the regulation constraint is atlevel 3.


ISO 10075-2( 4.2)

Recommendations

The Renault ergonomic analysis method evaluates the regulation possibilities on a scale of five levels ofconstraints using the "regulation" criterion. The regulation constraint should be at level "3.

The regulation criterion measuresthe possibility for the operator to:

!manage the components of industrial variability:! manage the diversity of the operations and commitments,! manage unforeseen events of malfunctions,

!achieve the production objectives in each work cycle,

!be able to vary his work speed slightly according to his physical and mental health,

!continue his activity temporarily during micro-breaks due to stoppages upstream or downstream of his station.

To favour regulation, it is recommendedthat the following elements be taken into account:

!Tack time. The possibilities for regulation fall with a reduction in the tack time.

!Work space in the case of continual advance of the product (the operator accompanies the advance of theproduct). The regulation space is determined by the technical and organisational elements such as: the lengthof the pipes of the equipment, the movement of the bench vices, the interference characterised by theoperators upstream or downstream, the type of supply on the line edge, etc.

!Operating modes. The operator should have the possibility of anticipating:! the lifting of parts and / or adequate tools,! the collection of information (anticipation several cycles before the arrival of a specific product).

!Synchronisation of actions. The synchronisation of operating sequences between several operators reducesthe possibilities for individual regulations by "imposing" a coordinated rhythm.

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F35 - Repetitive assembly operations - Postures

" There are no uncomfortable postures, significant twisting or flexing of the body,movements likely to cause illnesses or bodily injuries. Support for the body is

appropriate in order to avoid off-balance postures." Referring to the Renault ergonomic analysis method, the posture constraint is at level

3.


EN 614-1( 4.1.2 and 4.1.4)

Recommendations

The Renault ergonomic analysis method analyses postures on a scale of five levels of constraint. The postureconstraint should be at level "3. The table below reproduces an extract from the posture sheet for this method.

- Movements / mn> 20 m

- Climbing an obstacle> 500 mm

- Going up or down:-3 or more steps, hands full- step(s) with bulky load

- Stepping backwards >30% oftack time

- Crouching or kneeling forduration > 5 sec

Largeextension

backwards

or headlooking

$ 60

3

4

5

- Standing still with nopossibility of moving- Going up or down:- 1 or 2 steps, hands empty- Stepping forwards orsidewardswith posture level 3and with no interferencebetween operators

See table offittings and clips

See table of fittingsand clips

or

- Flexion or

extension of wrist> 60 and effort> 3Kg

- Risknoticedofperi-articularcomplaint

- Movements / mn

between14 and20 m- Climbing an obstacle ofbetween 300 and 500 mm

- Going up or down:- 1 or 2 steps, hands full- More than 2 steps, handsempty,

- Stepping sidewardswithposture level 4 or withinterference betweenoperators

- Stepping backwards# 30%of tack time

- Crouching or kneeling forduration of # 5 sec

See table offittings and clips

or

- Striking with hand

- Repeated rotations ofhand-forearm

- Considerablescrewing jolts

-Use of vibrating orpercussive to