PRINCIPLES AND APPLICATIONS

IN ENGINEERING Series

Engineering and
Administrative Controls

© 2003 by CRC Press LLC

 PRINCIPLES AND APPLICATIONS
IN ENGINEERING Series

Engineering and
Administrative Controls

EDITED BY

Waldemar Karwowski
University of Louisville
Louisville, Kentucky

William S. Marras
The Ohio State University
Columbus, Ohio

CRC PR E S S
Boca Raton London New York Washington, D.C.

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This material was previously published in The Occupational Ergonomics Handbook. © CRC Press LLC 1999.

Library of Congress Cataloging-in-Publication Data

Occupational ergonomics : engineering and administrative controls / edited by Waldemar

Karwowski, William S. Marras.
p. cm. — (Principles and applications in engineering ; 14)
Includes bibliographical references and index.
ISBN 0-8493-1800-9
1. Human engineering. 2. Musculoskeletal system—Wounds and injuries—Prevention. 3.
Industrial hygiene. I. Karwowski, Waldemar. II. Marras, William S. (William Steven),
1952- III. Series.

TA166.O257 2003
620.8'2—dc21
2002041399

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The Editors

Waldemar Karwowski, Ph.D., P.E., C.P.E., is Professor of Industrial

Engineering and Director of the Center for Industrial Ergonomics at
the University of Louisville, Kentucky. He holds an M.S. (1978) in
production management from Technical University of Wroclaw, Poland,
and a Ph.D. (1982) in Industrial Engineering from Texas Tech Univer-
sity. His research, teaching, and consulting activities focus on preven-
tion of low back injury and cumulative trauma disorders, human and
safety aspects of advanced manufacturing, fuzzy sets and systems, and
theoretical aspects of ergonomics.
Dr. Karwowski served as President (2000–2003) of the International
Ergonomics Association. He is editor of many international journals,
including Human Factors and Ergonomics in Manufacturing, and Theo-
retical Issues in Ergonomics Science, and consulting editor of Ergonomics.
He is the author or co-author of more than 200 scientific publications, including 25 books.
Dr. Karwowski is founder and chairman of the International Conference on Human Aspects of
Advanced Manufacturing and Hybrid Automation. He was the recipient of the Outstanding Young
Engineer of the Year Award, given by the Institute of Industrial Engineering. He was also a Fulbright
Scholar at Tampere University of Technology in Finland. He received the President’s Award for Outstand-
ing Scholarship, Research, and Creative Activity in the category of Basic and Applied Science at the
University of Louisville.

William S. Marras, Ph.D., C.P.E., holds the Honda Endowed Chair in

Transportation in the Department of Industrial, Welding, and Systems
Engineering at The Ohio State University, Columbus. He is also the director
of the biodynamics laboratory and holds appointments in the departments
of physical medicine and biomedical engineering. Professor Marras is also
the co-director of the Ohio State University Institute for Ergonomics.
Dr. Marras received his Ph.D. in bioengineering and ergonomics from
Wayne State University in Detroit, Michigan. His research centers around
biomechanical epidemiologic studies, laboratory biomechanic studies,
mathematical modeling, and clinical studies of the back and wrist.
His findings have been published in more than 100 refereed journal
articles and 12 book chapters, and he holds two patents, including one
for the lumbar motion monitor (LMM). His work has also attracted
national and international recognition. He has won the prestigious Swedish Volvo Award for Low Back
Pain Research and Austria’s Vienna Award for Physical Medicine.

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Contributors

Elsayed Abdel-Moty Patrick G. Dempsey Tarek M. Khalil

Department of Industrial Liberty Mutual Research Center for Department of Industrial
Engineering Safety and Health Engineering
University of Miami Hopkinton, Massachusetts University of Miami
Coral Gables, Florida Coral Gables, Florida
Bradley Evanoff
W. Gary Allread School of Medicine Jung-Yong Kim
The Ohio State University Washington University Department of Industrial
Columbus, Ohio St. Louis, Missouri Engineering
Hanyang University
Charles K. Anderson Paul Gaddie Ansan, Korea
Advanced Ergonomics, Inc. University of Louisville
Dallas, Texas Louisville, Kentucky Stephan Konz
Department of IMSE
Gunnar B.J. Andersson Katharyn A. Grant Kansas State University
Department of Orthopedic Surgery Robert A. Taft Laboratories Manhattan, Kansas
St. Luke’s Medical Center National Institute for Occupational
Chicago, Illinois Safety and Health Steven A. Lavender
Cincinnati, Ohio Department of Orthopedic
Michele C. Battié Surgery
Department of Orthopaedics Thomas Hales St. Luke’s Medical Center
University of Washington National Institute for Occupational Chicago, Illinois
Seattle, Washington Safety and Health
Cincinnati, Ohio Wook Gee Lee
Patricia Bertsche University of Louisville
The Ohio State University Simon M. Hsiang Louisville, Kentucky
Columbus, Ohio Liberty Mutual Research Center
for Safety and Health Chris J. Main
Ram Bishu Hopkinton, Massachusetts Department of Behavioural
IMSE Department Medicine
University of Nebraska Renliu Jang Hope Hospital
Lincoln, Nebraska University of Louisville Salford, England
Louisville, Kentucky
A. Kim Burton Richard W. Marklin
Department of Clinical Waldemar Karwowski Department of Mechanical and
Biomechanics Department of Industrial Industrial Engineering
Huddersfield Polytechnic Engineering Marquette University
Huddersfield, England University of Louisville Milwaukee, Wisconsin
Louisville, Kentucky
Don B. Chaffin William S. Marras
Center for Ergonomics Glenda L. Key ISE Department
University of Michigan Key Functional Assessments The Ohio State University
Ann Arbor, Michigan Minneapolis, Minnesota Columbus, Ohio

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Stuart M. McGill Malcolm H. Pope
University of Waterloo Department of Orthopaedic Surgery
Waterloo, Ontario, Canada Iowa Spine Research Center
University of Iowa
Raymond M. McGorry Iowa City, Iowa
Liberty Mutual Research Center
for Safety and Health Vern Putz-Anderson
Hopkinton, Massachusetts Applied Psychology and Ergonomics
National Institute for Occupational
Donald R. McIntyre Safety and Health
Interlogics Cincinnati, Ohio
Hillsborough, North Carolina
Robert G. Radwin
Stephen J. Morrissey Department of Industrial
State of Oregon Engineering
OSHA University of Wisconsin
Portland, Oregon Madison, Wisconsin
A. Muralidhar David Rempel
University of Nebraska University of California
Lincoln, Nebraska San Francisco, California
Robert W. Norman Valerie J. Rice
Department of Kinesiology U.S. Army Research Institute of
University of Waterloo Environmental Medicine
Waterloo, Ontario, Canada Occupational Physiology Division
Natick, Massachusetts
Ewa Nowak
Department of Ergonomics Richard G. Ried
Research The Ohio State University
Institute of Industrial Design Columbus, Ohio
Warsaw, Poland
Stephen N. Robinovitch
Mohamad Parnianpour San Francisco General Hospital
Department of ISE San Francisco, California
The Ohio State University
Columbus, Ohio Hubert L. Rosomoff
Comprehensive Pain and
Rehabilitation Center
University of Miami
Coral Gables, Florida
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Renee Steele-Rosomoff
Comprehensive Pain and
Rehabilitation Center
University of Miami
Coral Gables, Florida
Aboulfazl Shirazi-Adl
École Polytechnique
Montreal, Quebec, Canada
Carolyn M. Sommerich
ISE Department
The Ohio State University
Columbus, Ohio
Leon M. Straker
Curtin University of Technology
Shenton Park, Australia
Carol Stuart-Buttle
Stuart-Buttle Ergonomics
Philadelphia, Pennsylvania
Eira Viikari-Juntura
Department of Physiology
Finnish Institute of Occupational
Health
Topeliuksenkatu, Finland
Thomas R. Waters
National Institute for Occupational
Safety and Health
Cincinnati, Ohio
Richard Wells
Department of Kinesiology
University of Waterloo
Waterloo, Ontario, Canada
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Contents

Preface...................................................................................................................................................... xiii

PART I MUSCULOSKELETAL DISORDERS

SECTION I Disorders of the Extremities

1 Epidemiology of Upper Extremity Disorders Bradley Evanoff and David Rempel ....... 1-1

2 Integrated Analysis of Upper Extremity Disorders Richard Wells ............................... 2-1

3 Biomechanical Aspects of CTDs Richard W. Marklin....................................................... 3-1

4 Occupational Risk Factors for Shoulder Disorders Eira Viikari-Juntura.................... 4-1

5 Hand Tools: Design and Evaluation Robert G. Radwin ................................................... 5-1

6 Gloves Ram Bishu and A. Muralidhar....................................................................................... 6-1

7 Industrial Mats Jung-Yong Kim............................................................................................... 7-1

8 Ergonomic Principles Applied to the Prevention of Injuries to the

Lower Extremity Steven A. Lavender and Gunnar B.J. Andersson......................................... 8-1

9 Ergonomics of the Foot Stephan Konz ................................................................................. 9-1

SECTION II Low Back Disorders

10 Epidemiology of Back Pain in Industry Gunnar B.J. Andersson ................................... 10-1

11 Static Biomechanical Modeling in Manual Lifting Don B. Chaffin ........................... 11-1

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12 Dynamic Low Back Models: Theory and Relevance in Assisting the

Ergonomist to Reduce the Risk of Low Back Injury Stuart M. McGill...................... 12-1

13 Selection of 2-D and 3-D Biomechanical Spine Models: Issues for

Consideration by the Ergonomist Robert W. Norman and Stuart M. McGill................ 13-1

14 Quantitative Assessment of Trunk Performance Mohamad Parnianpour and

Aboulfazl Shirazi-Adl...................................................................................................................... 14-1

15 Perspective on Industrial Low Back Pain Malcolm H. Pope and Donald R. McIntyre ... 15-1

16 Revised NIOSH Lifting Equation Thomas R. Waters and Vern Putz-Anderson.............. 16-1

17 A Population-Based Load Threshold Limit (LTL) for Manual Lifting Tasks

Performed by Males and Females Waldemar Karwowski, Paul Gaddie,
Renliu Jang, and Wook Gee Lee...................................................................................................... 17-1

18 Occupational Low Back Disorder Risk Assessment Using the Lumbar Motion
Monitor William S. Marras, W. Gary Allread, and Richard G. Ried...................................... 18-1

19 Prevention of Musculoskeletal Disorders: Psychophysical Basis

Patrick G. Dempsey......................................................................................................................... 19-1

20 The Relative Importance of Biomechanical and Psychosocial Factors

in Low Back Injuries A. Kim Burton, Michele C. Battié, and Chris J. Main........................ 20-1

21 Fall-Related Occupational Injuries Stephen N. Robinovitch ............................................ 21-1

22 Low Back Pain (LBP) Glossary: A Reference for Engineers and Ergonomists
Simon M. Hsiang and Raymond M. McGorry ............................................................................... 22-1

PART II ADMINISTRATIVE CONTROLS

SECTION I Ergonomics Surveillance

23 Fundamentals of Surveillance for Work-Related Musculoskeletal Disorders

Vern Putz-Anderson and Katharyn A. Grant................................................................................. 23-1

24 Injury Surveillance Database Systems Carol Stuart-Buttle.............................................. 24-1

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25 OSHA Recordkeeping Stephen J. Morrissey......................................................................... 25-1

26 Body Discomfort Assessment Tools Leon M. Straker ...................................................... 26-1

SECTION II Medical Management Prevention

27 Medical Management of Work-Related Musculoskeletal Disorders

Thomas Hales and Patricia Bertsche............................................................................................... 27-1

28 Ergonomic Programs in Post-Injury Management Tarek M. Khalil,

Elsayed Abdel-Moty, Renee Steele-Rosomoff, and Hubert L. Rosomoff ......................................... 28-1

29 Physical Ability Testing for Employment Decision Purposes Charles K. Anderson... 29-1

30 Preplacement Strength Screening Valerie J. Rice .............................................................. 30-1

31 Assessment of Worker Functional Capacities Glenda L. Key ........................................ 31-1

32 Ergonomics and Rehabilitation Ewa Nowak ..................................................................... 32-1

33 Update on the Use of Back Belts in Industry: More Data — Same Conclusion
Stuart M. McGill............................................................................................................................. 33-1

34 The Influence of Psychosocial Factors on Sickness Absence Chris J. Main,

A. Kim Burton, and Michele C. Battié............................................................................................ 34-1

35 Back Pain in the Workplace: Implications of Injury and Biopsychosocial

Models Michele C. Battié, Chris J. Main, and A. Kim Burton................................................. 35-1

36 Upper Extremity Support Carolyn M. Sommerich ............................................................. 36-1

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Preface

Ergonomics (or human factors) is defined by the International Ergonomics Association (www.iea.cc) as
the scientific discipline concerned with the understanding of interactions among humans and other elements
of a system, and the profession that applies theory, principles, data and methods to design in order to optimize
human well-being and overall system performance. Ergonomists contribute to the design and evaluation of
tasks, jobs, products, environments, and systems in order to make them compatible with the needs, abilities,
and limitations of people.
Currently, there is substantial and convincing evidence that the proficient application of ergonomics
knowledge, in a system context, will help to improve system effectiveness and reliability, increase pro-
ductivity, reduce employee healthcare costs, and improve the quality of work processes, products and
working life for all employees. As ergonomics promotes a holistic approach in which considerations of
physical, cognitive, social, organizational, environmental and other relevant factors are taken into account,
the professional ergonomists should have a broad understanding of the full scope of the discipline.
Development of this book was motivated by the quest to facilitate a wider acceptance of ergonomics as
an effective methodology for work-system design aimed at improving the overall quality of life for millions
of workers with a variety of needs and expectations.
This book focuses on prevention of work-related musculoskeletal disorders with emphasis on engi-
neering and administrative controls. This volume contains a total of 36 chapters divided into two parts,
each of which is divided into two sections.
Part I focuses on engineering factors relevant to management of work-related musculoskeletal disor-
ders. Section I provides knowledge about risk factors for upper and lower extremities at work, while
Section II concentrates on risk factors for work-related low back disorders. The knowledge presented in
Section I includes epidemiology, biomechanics, and analysis of upper extremity disorders. This section
also includes discussion of occupational risk factors, shoulder, design and evaluation of handtools, gloves,
and industrial mats. In addition, information about injuries to the foot and leg is provided. The section
on low back disorders includes knowledge on epidemiology of back pain in industry, static and dynamic
low back biomechanical modeling, quantitative assessment of trunk performance, revised NIOSH equa-
tion, and population-based limits for manual lifting. In addition, this section discusses psychophysical
basis and psychosocial factors in preventing musculoskeletal disorders. It also includes a method for
assessment of risk of occupational low back disorders, occupational injuries due to falls, and provides a
useful glossary of low back pain terminology.
Part II focuses on administrative controls in prevention and management of musculoskeletal disorders.
Section I discusses fundamentals of surveillance of such disorders, requirements for surveillance database
systems, OSHA record keeping system, and surveillance methods based on assessment of body discomfort.
Section II focuses on medical management of work-related musculoskeletal disorders, including programs
for post-injury management, testing of physical ability for employment decisions, assessment of worker
strength and other functional capacities, and applications of ergonomics knowledge in rehabilitation.

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The use of back belts and supporting devices for upper extremities is also considered. Finally, the influence
of psychosocial factors and implications of back pain in the workplace is provided.
We hope that this volume will be useful to a large number of professionals, students, and practitioners
who strive to improve product and process quality, worker health and safety, and productivity in a variety
of industries and businesses. We trust the knowledge presented in this volume will help the reader learn
and apply the principles of ergonomics in prevention of work-related musculoskeletal disorders.

Waldemar Karwowski
University of Louisville

WIlliam S. Marras
The Ohio State University

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