The Frugal Ergonomic Engineer -The Sequel

The Frugal
Ergonomic Engineer
-The SequelBy Len Walsh
Engineering Fellow
Pratt and Whitney
IIE Applied Ergonomics Conference March 2004
Abstract
"The Frugal Engineer"
combines rather creative
engineering ergonomics
and unorthodox lean
manufacturing
techniques for those on
a very tight budgets.
!
The Frugal Engineer
In the words of Jeff Smith the celebrated
“Frugal Gourmet.” Frugal does not means
cheap, it is however, a good, practical use of
what available items you have already.
Sure you can spend money on ergonomics,
that is not the point. Practical, simple and
easy on the operator is the goal.
Webster's Defines
Frugal:
as avoiding unnecessary
monetary expenditures.
Or Mathematically
? + ! + $0.00 =$$$
and sometimes $$$$
Problem + insight + no budget =
$$$$!
The Real Problem Is People Stop
• When there is no budget to remedy problems.
• Give up goals, expectations and sometimes
hope.
• When the return on investment (ROI) has to
be some huge number, and proved out before
anyone acts.
• When people always remember how some
other project failed. So everyone wants to
avoid bad press!
What You Should Do, Is Look at
Problems As an Opportunity
To turn a process from a bunch of alligators …..
into handbags and turn a profit.
L.M. Walsh CDR USN
The Ergo Cycle
MSD
Recorded
Evaluate
/ Risk
Complaint
Devise Solution
Other
JHA
Pro Active
Intervention
Risk Factor
Implement Solution
Yes
Does
Risk Factor
Remain?
No
STOP
Job
Complete
No
The Bypass Cycle
MSD
Recorded
Evaluate
/ Risk
Complaint
Devise Solution
Other
JHA
Pro Active
Intervention
Risk Factor
Implement Solution
Yes
Does
Risk Factor
Remain?
No
STOP
Job
Complete
No
So let us look at some
of the rules for
frugal ergonomic
engineering..
10 Rules for the Frugal
Ergonomic
Engineer
Rule one
• You will always have problems
Rule two
• Problems always out number budget
Rule three
• You can proceed on any project for which you have
budget.
Rule 4
• You are given no budget.
Rule 5
• You can always, always get more projects, after you
have proven what you can do with no budget.
Rule 6
• Trust in yourself. Prove it, even if it means funding
and making it yourself. People like determination.
Rule 7
• Leverage and use the previous project time savings
and efficiencies to fund additional projects.
Rule 8
• Publicize.
Rule 9
• Always, always take money offered for other projects
once you have proven what you can do with little or
no money.
Rule 10
• Keep it simple.
Straight Razor
How do you cut pizza?
Cloth Rotary Cutter
Same Kind of Tool, Even Better
Screwdrivers
The common screwdriver has not
changed much until recently.
Torque Generated by Regular
Screwdriver
Triangular
Shape
Screwdriver Handle Shape
End view of the same screwdrivers reveals a
different geometry to the handle.
One of them is triangular in shape.
Tool Shapes for Optimum Grip
How much torque increase?
1x
3-5 x
Ideal Handle
1 1/4
Rounded edges
Parts
Washer
Nozzle
Spray nozzle adjustment
Difficult to
operate spray
nozzle was a
concern to
operators.
Gloves had to
be removed to
adjust spray.
Temperature
approached
160oF (71oC)
Nozzle
Adjustment
Made Easy.
Nozzle was outfitted with
three small plastic round
tubes, which were then taped
in place with electrical tape.
Shown above and right
before final layer was
applied. Similar to the
triangular screw driver shape,
this maximizes the torque
capability for the hands.
The Smile Says It All!
Operator trying his
newly modified
nozzle. (this time
with only warm
water.) Should be
no problem with
gloves on.
In case your
wondering, vinyl
electrical tape such
as 3M’s Scotch No.
33+ and 88 have an
effective
temperature range
of -40 to 220 F
Torque Wrench Hard on the Hand?
Then
Modify
It
Modified screw driver
(right) has a protective
cover that is triangular
shaped allowing 3-5
times the torque without
the painful gripping.
The new
Mountz torque
screw driver
Difficult to Handle Sizing
Wedges
Changed by
Addition of
a Handle
Inexpensive handle
made with local
materials.
Problem Deburring Parts With
Face Shield
The face shield is now held in place
with a former fluorescent light
fixture.
Sharp Edges on
Work Table
Transformed to soft
rounded edges with the
addition of foam rubber
pipe insulation
Using the Hands?
Convert a Detailing Brush
Low Cost
Solution
Modify a Used Brush With Velcro
What Can You Do With a Plastic
Fork?
Well in the Right Conditions
Velcro loop material added
You Can Scotch Brite Very Small
Areas Without Hurting Your Hands
Hand
Reaming a
Fiberglass
Component
Hard on the Hands Tap Handle?
Modify the Handle!
Use a short length of
rubber hose material
Small Scraper
Pinch grip is not a
desirable feature
of this tool.
Modified plastic
egg to accept the
scrapping blade
The egg is later filled
with RTV material to
provide a structure and
rigidity. Now a power
grip can be used to
control instead of a
pinch grip
Suppose You Had to Tear
Open Bags Like This?
You use a pinch grip to tear the bag open...
How much easier and faster,
could you do your job if you
mounted letter openers as a
third hand to help
Under a Kitchen Cabinet!
Mounted under a
kitchen cabinet, the
envelope cutter now
serves to open foil
lined pouches like
instant soups and
plastic bags.
Awkward Position of Hand
Modified With a
Former Paint
Brush
Modifying
an Existing
Cutter
A simple heavy duty
cable tie is used, that
is taped onto the
ends of the tool
Modified Tool in Use
Awkward Foot
Position
Transformed by the
addition of a simple foot
rest
Grit Blast
Material
(above) the grit blast
bag material is cut open
(right) Then dispensed
into the hopper.
Modification of the Grit Blaster
Interior Is
Modified
With a
Piercing
Star
Gravity of the bag over
the piercing star
eliminating debris and
cutting tools
Up and Down to Change Pressure
on Grit Blaster
Piping Is Modified and Brought
to the Front to Allow Easier
Control of Air Pressure
Modification of Work Station
Improvement of Part Orientation
Simple,
low cost
ideas are
sometimes
the best.
Changing the Orientation of Part
Makes It Easier on the Employee
Problem
• Blasting hose heavy
& cumbersome to
handle
• Users complained of
wrist, elbow, and
arm strains
Solution
• Two rings installed to
support weight of hose;
hose lengthened for
increased
maneuverability.
• Arm, elbow, and wrist
strains reduced.
Solution (cont.)
Closeup of support
ring (1 of 2 rings)
Small Allen Wrench
Modified
With Rolled
Paper and a
Soda Straw
Composite
Work
Stone Soup
Approach
Adding a Handle Allows Cart Use
Without Stooping Over.
Which Caused Some Intense
Competition to Arise Between Ergo
Committees
Rear View Mirror Takes on
New Meaning in the Office
Multiple Backpacks for School
Works well for
Jr. and Senior
High School.
One bag for
M-W-F another
for T-Th
Reducing Weight of Objects
Moved
Large 80lb bags
shown propped
up against
column replaced
with smaller
40lb bags.
Problem
• Home storage freezer being left open
slightly spoils food.
• Is there a way to avoid the situation?
• Can something be devised for low cost.
Application of
Bowline Knot
to the Freezer
door
Add a ½
Gallon
Orange
Juice
Container
Keeps Door
Closed
Variable weight capability
0 - 4.17 lbs
0 - 8.34 lbs
Tank Lid With
Easy Open
Counter
Weight
Tank lid is lowered and
raised via a wire rope. Lid
weight is counterbalanced
by gravity on a weight
suspended inside the
square tubing that supports
the pulley sheave.
Easy Open Lid
Counter weight is
safely and completely
enclosed
Shrink Wrap Machine
Able to handle large containers well but smaller boxes are a
problem to operators who reach in to position box
Eliminating Back Strain with
Light Weight Shuffle Board Stick
Depending on What Size Box Is
Used the Appropriate Light Weight
Aluminum Handle Is Used
Table for Riveting Machine
Simple
elevating
table allows
single
operator to
perform
riveting
operations
Tool
Suspension
System
Low Cost
Tool
Support
Looking From the Top Side of
the Freezer
Freezer Problems Eliminated
To eliminate the awkward bent over body positions used
when retrieving material, plastic milk crates were place in
the freezer, creating a raised shelf area or what is more
commonly called a false bottom. The net effect was raised
materials that were off the bottom and eliminate much of
the extremes while in the bent over position. Additionally,
the raised material had an added benefit, ice used to form
on the exterior of the rolls, which had to be removed or
caused the material to stick to the bottom of the freezer.
Now due to the raised false bottom, the ice build up and
potential to stick has been eliminated
Glare Problem?
Reducing
the glare
A bit of cardboard...
Grinding
Wheel Change
Over?
5 Gallon pail used to
eliminate the strain
and risk while
mounting wheels.
Open sides allow
access to allow
mounting without
interference!
Trash
Container
Problems?
Plastic bag remains set
in position unless
pushed down relieving
air.
Or becomes difficult to
remove when full.
Modified With Breather Holes
Allows the Trash to Be More
Easily Removed
Holes
Industrial
Version
Hole allows the trash can
liner to sit in the can and
also come out easier
Spray
Cans
Small spray tubes that are attached with
tape get lost frequently and are hard to
grasp.
With just a roll of tape
and a soda straw...
(above) Can with small tube attached
(right) can is outfitted with a bent soda
straw to allowing easy retrieval of a
small diameter spray tube. No more lost
tubes and storage problem solved.
Auxiliary Crumb Crusher
Found Using a Tuna Fish Can
•
•
During the holiday period I got the chance to experiment cooking some
interesting meals. Someone suggested I try Planet Hollywood Cap’n
Crunch Chicken. Intrigued by the sound of it and salivating at the
prospects I search the Internet for a possible recipe. I found something at
www.chicken.recipes-to-go.com As a retired Navy commander I always
have boxes of my favorite cereal on hand. However, the recipe called for
converting the cereal to crumbs. Some people had suggested using a
rolling pin or as others had suggested rolling a glass over it (can we say
carpal tunnel) or pounding it with a meat tenderizing hammer or another
mentioned they used their bare hands but complained about it. None of the
suggestions provoked any resemblance of anything terribly ergonomic to
me. A rolling pin would be far too big, the glass way too unfriendly to the
hand and a hammer far too damaging perhaps to the meal I was attempting.
Anyone around said yes the meal was quite good but making it was the
hardest part. Searching the immediate kitchen area I happened upon a
suitable tool
After all necessity is the mother of invention So the advantages are
something I can readily hold in my hand, small enough to cover the plastic
bag containing the cereal and yet perform the work desired in an easy
friendly manner and not invoke any pain or strain. Lesson learned using a
can of tuna fish 86 Cents. Lesson learned about ergonomics and the desire
to fit the tool to the person and a message to convey to others as always
priceless!
Another Use for Duct Tape?
Known as one of
the greatest
contributions to
engineer science.
Duct tape has
remarkable
ergonomic
capabilities as
well.
Duct Tape Vacuum Cleaner
More
powerful than
an 8 HP
vacuum
cleaner.
Inverted duct
tape wrapped
around the
foot does a
remarkable
job cleaning
up.
By indexing duct
tape around the
foot, full strength
vacuum qualities
are maintained.
Additionally, the extra stretching, walking and
exercise is good for the heart. And good family fun
too and everyone will want to join in. But please
keep away from small children and textured ceilings
Lifting of Step Ladder
Sharp
edge on
fingers
Modified with a piece of foam to
lessen impact to hand
Modified Scoop
Easier on the Back
(above) Overall length of the scoop
was 33 inches, much too short for
taller people to use without stooping
over. ( right) Modified scoop with 10
inch ( 25.4 cm) extension handles.
Sharing the Information Globally
Conclusion
Everyone will tell you to think out of the box.
However, I believe that is well overused such
that everyone is doing that. What you need
to do is “think outside your industry” for
logical answers. Sure you can spend money
on ergonomics, that is not the point. Fund
and prove budgets for ergonomics by making
a difference to the bottom line with frugal fixes
and when extra budget is required you have
precedence. Practical, simple and easy on
the operator has always been the goal.