Introduction to EAWS
Introduction to EAWS
The need to identify the degree of exposition to biomechanical load has led at the beginning of the new millennium to the development of specific ergonomic risk screening tools; aim of these tools is to analyze the risk factors that may lead to overload the operator and eventually to occupational diseases. As always, the final goal is the redesign of the work system so that the any risk can be minimized and the performance eased.
The basis of every ergonomic risk screening tool is to estimate the correlation between the task ergonomic characteristics (force, frequency, postures, etc.) and the probability to cause an occupational disease. The main difficulty is to establish how the different factors interact and lead to work related troubles or diseases.
Certainly the best approach is the prevention of the risk in the design phase of the work system (preventive ergonomics); if the product and/or the process is already defined, changes may be too costly and less efficient (corrective ergonomics).
For a quantitative ergonomic risk evaluation of a specific working sequence, generally two evaluation levels are used:
- First level tools: risk screening tools which require a quick checklist.
- Second level tools: risk evaluation tools which require a detailed analysis with index calculations. They are applied where a possible risk has been already detected by a 1st level system and the “risk generator” is not yet well identified.
The aim of First level tools is to get a very quick mapping of the different risk areas and to concentrate all the efforts on a rapid redesign. With the Second level tools specific loads are analyzed in detail, since the first level corresponding tool was insufficient to identify the origin of the risk.
Though the EAWS is presented as First level tool, it is quite analytical and it always identify the origin of the risk.
In the following table the risk areas, the correlated standards and the most common ergonomic tools are summarized.
The EAWS project
The needs to comply with the standards pushed the companies to have at their disposal a 1st level ergonomic analysis system to evaluate the biomechanical load in its components (postures, forces, etc.) for the whole body. The EAWS meets these requirements. During its development in particular the following design criteria were taken into account:
- The tool had to be accepted and considered exhaustive by:
- Applicator deviations – e.g. the gap between the analysis results of different applicators – had to be minimized, rendering the identification and measuring of technical actions, awkward postures and forces at maximum objective.
- The tool should have the capability to be used during the planning of the product/process as well as in the production process.
The main aims of the development of the EAWS system were:
- Compliance with labor legislation (national and international), e.g.:
- EU Machinery Directive (2006/42/EC, former 98/37/EU, 89/392/EEC)
- EU Framework Directive (89/391/EEC)
- Allow to document and evaluate the working conditions, taking into account the operator work load as it is described by the existing ISO/CEN standards
- Ensuring ergonomic working conditions
- Developing an extension of the Automotive Assembly Worksheet (AAWS) for repetitive loads on the upper limbs in accordance with EN 1005-5 and the corresponding ISO standard 11228-3.
- Making this tool usable in any kind of production system, from mass production to one of a kind production
- Developing a free tool without any kind of copyright
- Linking EAWS to MTM:
- MTM-2 : mass production systems
- UAS: batch production systems
- MEK: one of a kind production systems
Project development history
EAWS is originally an extension of the Automotive Assembly Worksheet (AAWS) developed by the IAD (Institut of Ergonomics at the Darmstadt University of Technology) on the basis of the “New Production Worksheet”, initiated 1997 by General Motors Europe (GME), and the “DesignCheck”, realized at the same time at Porsche. The development of the EAWS was carried out between 2006 and 2008, by occupational health, biomechanical and industrial engineering international experts from all over the world, coordinated by the IMD (International MTM Directorate).
The field test was run in multinational companies that allowed the team to analyze relevant processes that represented different production contests. In this way all the necessary tests were performed before the last release of the tool (Field Application Group).
In addition, software companies were involved during EAWS development in order to implement and develop specific software solutions based on EAWS structure (Engineering Application Group).
IMD and national MTM Associations, together with the experts that worked with the team, gave all the tests results to the reference teams that represent the EAWS users main process partners (Reference Groups). The general project organization during the development phase was the following:
EAWS project development organization
Field Application Group:
ITALY AND FRANCE
- MTM Italia
- FIAT auto, Mirafiori Torino Plant
- BOSCH Diesel Technologies and Breaking Systems (BA)
- WE: Whirlpool Europe (Home Appliances), Amiens plant, France
- IVECO: commercial vehicles, Suzzara plant
- Volkswagen: automotive (IAD)
- Bosch: (IAD)
- Macro-Section “Whole body”:
- Macro-Section “Upper limbs”
- For a quick ergonomic risk assessment on an observed specific worker performing the work task on the shop-floor (observational method)
- Paper & pencil tool à two double-sided A4 sheets with interpolation
- Analysis refers to observed work task and operator (deviation risk from planned method)
- Risk factors estimated by users (forces, durations, frequencies, etc…)
- ergonomic risk assessment of the workstation on a generic worker performing the standard work task (MTM method)
- Software tool: IVGA (Excel based)
- Useful to assess the ergonomic impact of method improvement opportunities
- For a preventive and analytic ergonomic risk assessment on an anthropometric group of operators performing a work task (MTM method)
- Software tool: TiCon – MTMergonomics®
- Inputs needed:
- MTM task analysis
- Production plan for frequencies calculation
- MTM codes ergonomic characterization (geometries, forces, weights, etc…)
- Production flow macro-geometries (heights) and product positions (high, low, etc…)
- FIRST PAGE:
- SECOND PAGE:
- THIRD PAGE:
- FOURTH PAGE:
– A. Tassinari, International MTM Instructor (PwC)
– C. Rubano, MTM Instructor (PwC)
– Planning & Control: L. Galante, R. Bonetti, M. Capoccia, M. Vitello
– Ergonomy: F. Leoni
– Work Analysis: G. Condò
– K. Schaub
– Ergonomy: B. Toledo Munoz, R. Filus
– Bosch- Siemens home appliances
– Bosch Rexroth tools
EAWS: Structure and basic principles
EAWS is an ergonomic tool for measuring the workload generated in a workstation by a given working method (motion sequence, workplace geometries, postures, equipment, parts, conditions) executed according to a given production plan (quantity and production mix) with a given work organization (shift duration, pauses). EAWS can also be used as a an ergonomic 1st level risk screening tool providing an overall risk evaluation, where the risk is due to any biomechanical load. Up to a certain extent EAWS can also be used as 2nd level analysis tool, since it is quite analytical and detailed; EAWS gives the necessary information to redesign the work task, making the second level systems seldom necessary.
ISO 11228.2 Risk assessment model
The risk assessment model is defined more comprehensive in the International Standard ISO 11228 Part 2 (Pushing and Pulling) at page 3.
The structure of the analysis is as follows:
– Section 1: Body Postures
– Section 2: Action forces
– Section 3: Manual materials handling
The EAWS sheet provides one score resulting for each Macro-Section which is exposed in a traffic light scheme (green, yellow, red) according to the Machinery Directive 2006/42/EC (EN 614).
Figure 16 – Overall Evaluation
Whole body and upper limbs scores are evaluated on the same scale.
EAWS modes of use and basic structure
The EAWS system can be used in two different modes, which differ in scope and calculation procedure:
“Instantaneous” risk mapping\preliminary workstation re-design for a specific worker
Quick workstation re-design
ERGO-MTM workstation design
EAWS basic structure
The basic EAWS form structure is the following:
– Result of overall evaluation (where results of each section are reported)
– Section 0: Extra Points
– Additional information for scoring repetitive tasks (cycle time, produced units, breaks, etc.)
– Section 3: Manual materials handling
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Minimizing stress situations
“We’re also carrying out process analyses in the nursing area. This has the crucial benefit that it is easier to plan human resources needs, minimize stress situations and, at the same time, guarantee excellent nursing care or even improve it.”
Dr. Stefan Beyer, Managing Director, Vital-Kliniken GmbH
Ergonomics and economics
“MTM makes a significant contribution towards reconciling an increase in productivity and ergonomics. Because the basis for any increase in productivity is firstly the technical preparation work, the industrial equipment, but also the work design for the employees. When there’s an increase in productivity, there’s greater physical pressure for the employee – and the MTMergonomics analysis allows us to classify the level of this pressure.”
Harald Ebner, Head of Disk Brakes Unit, Knorr-Bremse Systeme für Nutzfahrzeuge GmbH, Aldersbach
"The introduction of the ERGO-UAS system has dramatically changed the way of developing the new products and of managing Production and the Industrial Relations. No motion can be designed, implemented and executed in our company without the scientific assessment of the biomechanical load generated by the motion itself. The paradigm "more productivity less health" has been turned into the new "more productivity more health" and the ERGO-UAS system has become one of the fundamental pillar of our production system"
Luigi Gennaro Galante, VP Manufacturing EMEA, Fiat Group Automobiles SpA