EPRI Ergonomic Issues for Specification SelectionSpecification, Selection, Design, Upfitting and Maintenance of Fleet Vehicles

EEI Occupational Safety & Health CommitteeLoews Lake Las Vegas Resort 10/06/09Loews Lake Las Vegas Resort 10/06/09

Patricia Seeley CPE

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yErgonomics Solutions, LLC; Marquette University; EPRI

AcknowledgmentsAcknowledgments• Gabor Mezei, MD, PhD, EPRI Program Manager, , , g g• EPRI OHS Committee• Richard Marklin, PhD, CPE, MarquetteRichard Marklin, PhD, CPE, Marquette

University• Steve Freier and Kyle Saginus, Graduate Research

Assistants• Amy Stone, OTR, Marquette UniversityJ l C i Ri h d D i k W E i• Jewel Currie, Richard Dwornick –We Energies

• Richard Dwornik—fleet We Energies

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It is an honor to be here• Thanks to EEI for inviting me• Thanks to EEI for inviting me • At EPRI we are listening—

• Hybrid• Ergonomically designed

• By whom?• Using what data?

A i kf• Aging workforce

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Thi t tiThis presentation

• EPRI’s role in ergonomicsE i d fl t hi l• Ergonomics and fleet vehicles

• Feasibilityy• Methodology• Sample vehicles concerns• Sample vehicles, concerns• What can you expect from this

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project?

Sho of hands ho antsShow of hands—who wants…• Greater standardization• Greater standardization• Vehicle specifications

• Cost effective• Feasible• Get the work done

• Scientifically differentiate between yneeds vs. wants

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EPRI fleet design project goals• Add ergonomics criteria to fleet specifications• Add ergonomics criteria to fleet specifications

for design and upfitting through • Database of worker anthropometry for use in fleet p y

specifications• Database and 3D modeling of many vehicles, upfits• Utility worker 3D modeling• Utility worker 3D modeling

• Enhance the working relationships in utilities among IT, operations, fleet to improve g , p , pproductivity and worker health

• Capture ergonomic concerns and solutions f fl t i t

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for fleet maintenance

What do we need with a fleetWhat do we need with a fleet process?

• We have Henry• He looks a lot like

Homer• He’s retiring next g

year

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EPRI and Ergonomics

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EPRI the Electric Power ResearchEPRI, the Electric Power Research Institute Ergonomics Studies:

1999 20111999-2011• Overhead line mechanics• Two underground line mechanics

studies• Power plant electricians• Power plant operators and mechanics• Power plant operators and mechanics• Power plant design

EPRI the Electric Power ResearchEPRI, the Electric Power Research Institute Ergonomics Studies:

1999 20111999-2011• 23 funding utilities representing a large fraction of

US electric utility customers—y• Program 62 in the EPRI • environment sector

W E i f Mil k WI• We Energies of Milwaukee, WI—host utilityhuge in-kind contributionhuge in kind contribution worker ergonomics teams

• Teams worked with Marquette University

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Previous design and guidelinePrevious design and guideline studies

• Ergonomic design for fossildesign for fossil power plant constructionconstruction completed 2008

• Engineering training

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gprograms

What’s ergonomics got to do, t t d ith it?got to do with it?

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It’s not just the agingIt s not just the aging workforce

• We can’t fire themthem

• We can’t line them up and shoot them

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What ergonomics is about

• The fit between the worker and their

kwork• Engineering

controls to fix thecontrols to fix the work for a group of people

• Proactive—do it in the design phaseA id t fit

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• Avoid retrofits

Simple things pile upup

• If the work-worker fit is poor, even short durations can add up to long termadd up to long term soft tissue injury

• MSDs—MSDsmusculoskeletal disorders

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Think of ergonomics issues asThink of ergonomics issues as illnesses not injuries

• MSDs don’t developdevelop overnightThe treatment• The treatment is not a simple fix eitherfix either

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Some TypicalSome Typical “Ergonomic” Illnesses

Pitcher’s Shoulder (Rotator Cuff Tendinitis)Pitcher s Shoulder (Rotator Cuff Tendinitis)and Bursitis

Tennis and Golfer’s Elbow(Epicondylitis)(Epicondylitis)

Low Back Pain

Carpet Layer’s Knee (Bursitis)

Carpal Tunnel SyndromeCarpal Tunnel Syndrome

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If ergonomics were just “common sense” …

• Not fun to operate• Not fun to operate this newly installed handwheel—too low, girders in the way

• Won’t matter—infrequent

ti i ht?operation, right? • But when it needs

i tmaintenance, no way to get there

Bart has this toBart has this to say about that

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It’s about data• EPRI already has relevant data from 16

utilities, 13 years• Crashes, incidents

• Backing up• Unintended acceleration• Unintended acceleration

• Injuries,illnesses• Lower back disordersLower back disorders • Other MSDs

• We are using data, investigating

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relationships

Anthropometry study

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The rule of anthropometry• “Let the large man

fit, let the small woman reach”

• This one size-fits all- work height shown here fits only one not allone, not all

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Anthropometry—theAnthropometry the measurement of human size,

capability is importantcapability-is important• Vehicle manufacturers

routinely design for the 50th percentile male

• Assemble database ofAssemble database of utility field employees critical dimensions to di ithdiscuss with manufacturers and have better basis for

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specifications

Remember the story ofRemember the story of Goldilocks

• One bed was too hard• One bed was too soft• One was JUST right

• Just right can be a matter of opinion on psome things

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J t i ht l bJust right can also be a necessitynecessity

• Have you ever had b k i ?back pain?

• Have you…been too small or too bigsmall or too big to….

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How do we know?

• How can we tell manufacturers that • our workers do not fit into our vehicles?our workers do not fit into our vehicles?• The range of adjustability does not

accommodate a majority of our workforcesacco odate a ajo ty o ou o o ces• We have special anthropometric needs

because our workforce is different from the general population

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We have to measure them• EPRI tried this in 1984• They had a limited sampleThey had a limited sample• They didn’t actually measure people:

workers told themo e s to d t e• Their height• Their weightg• Pants/shirt sizes

• Even so they did not get enough

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y g gwomen or enough participants

Conduct site visits:Conduct site visits: anthropometry

• Measure the workforce• Develop a statistically significant p y g

database of worker dimensions relevant to vehicle design• Sitting dimensions• Pants length, boot size• Standing functional reach, stature• Weight and Girth: how obese are field/

generation tilit orkers?

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generation utility workers?

Peoplesize software

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Preliminary results

• Electric utility workers are approximately at the 75th percentile ofapproximately at the 75 percentile of the general population for • HeightHeight• weight

• This has HUGE implications for design• This has HUGE implications for design and upfits

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How does that airplane seat fitHow does that airplane seat fit you—9 hours to Europe?

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Let’s get real

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Tradeoffs in features, adjustability• Manufacturers and

upfitters will do anything to please their

tcustomers….as long as they are willing to paywilling to pay premium prices

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Desires vs feasibility tradeoffsDesires vs. feasibility—tradeoffs in adjustability

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Tradeoffs inTradeoffs in location • There is only so

h thmuch room on the truck

• Not everyone will• Not everyone will like where the committee decided to put things

• Where the water cooler is situatedcooler is situated may be more important in hotter

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pclimates

Hence guidelines and bestHence, guidelines and best practices are targets,

t d tnot mandates• It won’t mean a• It won t mean a

bulls eye on every issue

• Marksmanship will lead to improvements in artistry and raise

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the bar for everyone

Sample Vehicles

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A i l T k40

Aerial Truck

Pickup Truck

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Van

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Service Vehicle

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Digger Derrick

Box Truck

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B lld46

Bulldozer

Sample ergonomic concerns

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Let’s start with an example of whyLet s start with an example of why anthropometry is so important

V hi l f t ft th• Vehicle manufacturers often use the 50th percentile male (trucks) or female (cars)(cars)

• Designing to 50th percentile excludes many people (short tall obese etc )many people (short, tall, obese, etc.) thus resulting in

POOR FITPOOR FITbetween vehicle and many users

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between vehicle and many users

A l t d l lAccelerator pedal clearance

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“These boots are made for walkin’ ”These boots are made for walkin …• Vehicle manufacturers

design to the 50th maledesign to the 50 male percentile

• For boots—that allows f th b t t fitroom for the boot to fit

safely on the pedals for width and length

• Army data1—average male shoe size • 1776 size 6 5• 1776 size 6.5• 1980 size 9

• No current studies

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1National Shoe Retailers Association, 2009

Percentile assumptions make aPercentile assumptions make a big difference at the pedals

US Male shoe size

Foot length Foot width

9C (50th???) 10 1/3” 3.7”

12 D (“bread and butter” size1)

11 1/3” 4.3”

15E 12 1/3” 4 8”15E 12 1/3” 4.8”

18EEE 13 1/3” 5 6”

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18EEE 13 1/3 5.6

1National Shoe Retailers Association, 2009

How big is a size 13, size 15 or even size 18 winter boot?even size 18 winter boot?

It matters in Iron Mountain, MI

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Accident/injury investigationsAccident/injury investigations into “unintended acceleration”

• “boot caught under the brake pedal”• “unintended acceleration” when boot• unintended acceleration when boot

hit the underside of the dash trying to brake rotating heel on pivot point hitbrake, rotating heel on pivot point hit the accelerator pedal

• same people whose legs run into the• same people whose legs run into the instrument panel and steering wheel on light duty trucks

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light duty trucks

Other sample vehicle issues

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I wanna stretch my legs..

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Knees hit steering wheel: 6 ft heightKnees hit steering wheel: 6 ft. height is not unusually tall for field workers

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Laptops—trend away from MDTs

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M bil t h lMobile technology concerns

• Twisted posture• Unsupported right pp g

arm• Congestiong• Wrist deviation

and extension

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Ladders are used all the time

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A better design

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Poor bucket access—still a lot ofPoor bucket access still a lot of these out there

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Other access issues

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Window pinch points

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Pinch points

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MSD concern for storage of andMSD concern for storage of and removal of equipment, tools, materials

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Access and congestion

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This one is even worse!

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Cabinets

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I /E t dIngress/Egress—steps and handleshandles

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Poor vehicle access

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Aerial bucketAerial bucket controls

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Where to put it? Here or there?Where to put it? Here or there?

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Methodology and Process

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Literature ReviewLiterature Review• ANSI/SIA A92.2-2001

Aerial Devices• Federal Motor Vehicle

Safety Standard • SAE standards (36 soSAE standards (36 so

far)• European ergonomics• European ergonomics

standardsL l d t t

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• Local and state regulations

The largest body of literatureThe largest body of literatureis proprietary—yet not every vendor has ergonomist design engineershas ergonomist design engineers—there are <700 CPEs in the US

• Like the previous EPRI studies we will l l ti hi t i fl d ileverage relationships to influence design

• We will also reach out to other manufacturers who may have a relatively

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manufacturers who may have a relatively unknown product

Site visits around US, Canada

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The most important task: interview theThe most important task: interview the workers (but don’t buy into agendas)

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Conduct Site Visits at Utilities:Conduct Site Visits at Utilities:Measurements of Cab and Upfits

Laser measuring tape

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Conduct Site Visits to Utilities:Conduct Site Visits to Utilities: Measurement of Cab and UpfitsConventional measuring tape and stick

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Conduct Site Visits to Utilities:Conduct Site Visits to Utilities: Measurement of Cab and Upfits

Inclinometer

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Conduct Site Visits to Utilities:Conduct Site Visits to Utilities: Maintenance

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Conduct Site Visits to Utilities:Conduct Site Visits to Utilities: Maintenance

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Scaffolding

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• Remember ALL your tools• Climbing may require a one armed body lift

Conduct Site Visits to Utilities• Digital still

photographs• Digital video• We write site visit

reports for each utility

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3D modeling for ergonomics

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Data and Analysis:Data and Analysis:3-D Modeling NX6

• Industry standard• Reasons for 3-D modeling

• Anthropometric analysis• Range of motion• Comfort• Accommodate the widest range of users

• We will have a database of 50

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e a e a database o 50vehicles—currently 30

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Onsite line drawings

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3 D Modeling:3-D Modeling:International Harvester Aerial 4300

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3 D Modeling:3-D Modeling: Chevy Silverado 3500 Pickup

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3 D Modeling:3-D Modeling: Chevy Silverado 3500 Pickup Interior

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3-D Modeling: ChevyChevy Silverado 3500 Pickup Interior withInterior with laptop

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Data and Analysis 3-D Modeling:Data and Analysis 3-D Modeling: The next step: Jack - Reaches

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Jill has the tougher task

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Jack has it easJack has it easy

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95th percentile Jack modeling95th percentile Jack modeling use of laptop

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95th percentile Jack modeling95th percentile Jack modeling use of laptop

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50th percentile Jill

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50th percentile Jill

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Laboratory studies

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Lab study : 2009-2010Lab study : 2009-2010Vehicle mounted laptops

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Laptop configurations

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What do EPRI members get t f thi ?out of this?

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Number vs. cost of interventionsEPRI overhead line worker ergonomics study (2001)ergonomics study (2001)

Initial Costs for Line worker ergonomic interventions

> $1000

interventions

$0 $100

$100 - $1000

> $1000

0 5 10 15 20

N b f i t ti

$0- $100

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Number of interventions

Fleet Study 2008-2011

A Systematic Method for Specification, Purchase and Upfitting of FleetPurchase and Upfitting of Fleet Vehicles in the Electric Power Industry• Ergonomic Design and Maintenance ofErgonomic Design and Maintenance of Original and Upfitted Fleet Vehicles • Process Guidelines for SpecificationProcess Guidelines for Specification, Purchase, and Upfitting of Fleet Vehicles

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Rules of thumb 2009Rules of thumb 2009 guidelines

• Ingress/egress• Preliminary design y g

guidelines• OHS Committee

members demand it

NOW!!!NOW!!!

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Vendors and Manufacturers• Interaction with the• Interaction with the

vendors and mfg is importantimportant

• Identify the research id f b dvoids of cab and

storage design of fleet hi lvehicles

• Influence them to

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improve the interface

B fitBenefits

• Best practices of design, upfitting rather than re-inventing the wheel

• Best practices in ifi ti fittispecifications, upfitting,

maintenance and processN d t f ibl• Needs vs. wants—feasible cost-tradeoffs

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Sample best practice upfits

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Sample best practice upfits

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Access to small items

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Worker designedgcompartment dividers

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D li blDeliverables• November 2009 Rules of thumb—critical

dimensions guidelinesdimensions guidelines• November 2009 and 2010

• Progress reports• Winter 2011—2 handbooks

• Specification, upfitting, maintenance recommendations• Process guidelinesProcess guidelines• Databases• Downloadable and on CDP bli h d ti l• Published articles

• Anthropometry study• Laboratory studies

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• Laboratory studies

Guidelines • Ergonomic and safety hazards/risk factors• Ingress/egress• Seating• Access/storage• Special equipment (outriggers, safety cones)

L t GPS th t h l• Laptops, GPS, other technology• Special vehicle types (aerials, digger

derricks pickups vans service trucksderricks, pickups, vans, service trucks, dozers, chippers, trenchers, dozers)

• Visual issues (mirrors, lighting, backup

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( , g g, psystems)

What do you needWhat do you need to do?

• It’s no good if it sits on the shelf, if onlyIt s no good if it sits on the shelf, if only H & S gets it• Who is your EPRI METT(rep) y ( p)

• Get the reports, guidelines• Is your utility in the EPRI environmental

? ( )group? (most are)• Yes—program 62 costs no more money

• Not in the study vendor?• Not in the study, vendor? • Join!• Purchase the studies• EPRI best sellers• http://www.epri.com- search for ergonomics

Once you get it

• Review for relevance to your utility• Select priorities• Select priorities• Conduct training• Involve everyone

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Patricia SeeleyPatricia Seeley• ergo@wi.rr.com • 262 370 2417

Richard Marklin EPRI PIRichard Marklin, EPRI PI• Richard.marklin@marquette.edu• 414 288-3622

G b M i EPRI P MGabor Mezei, EPRI Program Mgr • GMezei@epri.com

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@ p• 650 855 8908

Thank you!!!•Questions???

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