A Heavy Engineering Design Checklist

Skepper, N., Straker, L. and Pollock, C.

Background

This checklist was developed as a guidance tool to assess operational engineering designs in the oil and gas industry. It was developed as part of a research project on the use of ergonomics in the engineering design process. Details of the project are being reported elsewhere (Skepper, Straker and Pollock 1998; Skepper, Straker and Pollock, in preparation).

The literature was reviewed extensively to identify potentially suitable checklists. Whilst many checklists were identified (for example: Ergoweb, 1997; International Labour Council, 1996; Workplace Health and Safety, 1996; DOHSWA, 1995; Howarth, 1995; DOHSWA, 1994; Straker, 1994; Dul and Weerdmeester, 1993; Sanders and McCormick, 1993; Ostrom, Gilbert and Hill, 1992; Pulat, 1992; Woodson, Tillman and Tillman, 1992; McClelland, 1990b; Meister, 1990; Stammers, Carey and Astley, 1990; Drury, Paramore, Van Cott, Grey and Corlett, 1987; Grandjean, 1985; Frederick, Habes and Sloemer, 1984; Eastman Kodak, 1983; Productivity Promotion Council, 1979) none were suitable for this research project.

Therefore a new checklist was developed. Relevant topics were chosen from the checklists in the literature and combined into 7 major headings including general, work environment, equipment, work practices, physical and psychological task demands, organisational issues and employee characteristics. The safety issues not included are listed at the end to clarify their intentional exclusion from this checklist.

The topics were organised so that an engineering design could be evaluated in a short period of time. Space was allowed for comments next to each point and possible responses included yes, no or not applicable, choice being indicated with a tick under the relevant response. A "no" response was designed to indicate situations which may be associated with higher risk of injury or illness or which may be contributing to ergonomic risk.

References

Skepper, Straker and Pollock (1998) Ergonomics in the engineering design process. In: Implementing change: the role of standards: Proceedings of the 34th Ergonomics Society of Australia Conference, Melbourne.

Skepper, Straker and Pollock (in preparation). The use of ergonomics information in a heavy engineering design process. for Applied Ergonomics


 

Heavy Engineering Design Checklist

Narelle Skepper, Leon Straker and Clare Pollock

Advanced Personnel Management and Curtin University of Technology
Perth, Western Australia


Date:

Project Title:

Description of Project:

(Include photograph)





Checklist information received from:

*

1

GENERAL

What information is required to complete the task?
Is the task clearly defined?
Were end users involved in the design and installation of the project?
Are the end users aware of who the designers and installers of the project are?
Were indirect users considered during the design and installation stage of the project?
Was an implementation strategy agreed to by all parties?

*

Note:

  • A "No" response indicates situations which may be associated with higher risk of injury or illness or may be contributing to ergonomic risk.
  • Under Comments: O = Observation and U = User Statement

2

WORK ENVIRONMENT

Yes

N/A

No

Comments

2.1

Climate
Are employees only exposed to a comfortable climate? . . . .
  • Is the temperature comfortable?
. . . .
  • Does the temperature not interfere with the task?
. . . .
  • Are employees exposed to work areas that do not have drafts?
. . . .
  • Is the atmosphere clear of contaminants and toxic substances?
. . . .
  • Are employees exposed to clean, fresh air always?
. . . .
  • Are employees able to avoid exposure to high levels of humidity?
. . . .

2.2

Noise
Does noise optimise human/ work interaction? . . . .
  • Is noise level comfortable?
. . . .
  • Are noise levels in the work environment not distracting?
. . . .
  • Is noise level not interfering with communication?
. . . .
  • Are auditory signals easy to hear?
. . . .
  • Are employees exposed to loud noise for less than 5 minutes?
. . . .

2.4

Vibration
Does vibration optimise human/ work interaction? . . . .
  • Are vibration levels comfortable?
. . . .
  • Do vibration levels not interfere with communication?
. . . .
  • Are shocks/ jolts absent from work environment??
. . . .
  • Does annoying vibration from hand machinery affect task performance?
. . . .
  • Do vibration levels allow for adequate task performance?
. . . .

2.5

Lighting
Does lighting optimise human/ work interaction? . . . .
  • Is lighting sufficient to allow adequate task performance?
. . . .
  • Are lighting levels comfortable?
. . . .
  • Are all globes/ tubes operating?
. . . .
  • Are light fittings clean and in good order?
. . . .
  • Are excessive contrasts in work environment avoided?
. . . .
  • Is the light bright enough during the day-time?
. . . .
  • Is the artificial light bright enough?
. . . .
  • Is the emergency lighting operational?
. . . .
  • Are light sources arranged to avoid shadows?
. . . .
  • Is looking from a bright area to a dark area avoided?
. . . .
  • Is lighting steady ie. no flickering fluorescents, tubes out of phase or no stroboscopic effects from machinery?
. . . .
  • Are employees able to detect defects easily under current lighting conditions?
. . . .
  • Is glare avoided?
. . . .
  • Is excessive brightness avoided?
. . . .
  • Are fine colour differences easily distinguished?
. . . .

2.6

Floor Surfaces
Do floor surfaces optimise human/ work interaction? . . . .
  • Do floors have a nonslip surface?
. . . .
  • Are floors even?
. . . .
  • Are trip hazards eliminated from environment?
. . . .
  • Are drains/ pits covered or barricaded if not in use?
. . . .
  • Are surface spills wiped up quickly eg grease/ oil/water?
. . . .

2.7

Layout
Does layout optimise human/ work interaction? . . . .
  • Does layout permit adequate access for use/ movement of equipment?
. . . .
  • Is there adequate clear space for moving legs and feet?
. . . .
  • Is workplace layout large enough to accommodate safe work practices?
. . . .
  • Does workplace layout allow for efficient work motions?
. . . .
  • Is adequate workspace available for use of equipment?
. . . .
  • Are aisles/walkways wide enough for equipment and pedestrian traffic ie. 1.2 m passage and 810 mm doors?
. . . .

3

EQUIPMENT

Yes

N/A

No

Comments

3.1

General
Does equipment supplied allow task to be completed efficiently and safely? . . . .
  • Are appropriate tools/equipment available?
. . . .
  • Does equipment have machine guarding, if appropriate?
. . . .
  • Are starting/ stopping devices within easy reach?
. . . .
  • Are mechanical handling aids provided eg. trolleys, air hoists, scissor tables?
. . . .
  • Does furniture (eg tables/ chairs) provide good adjustability?
. . . .
  • Are hand tools easy to grasp?
. . . .
  • Are all rungs present on ladders?
. . . .
  • Do staff have control over equipment bought?
. . . .
  • Do staff have control over equipment used for job?
. . . .

3.3

Controls/ Displays
Do controls/ displays optimise human/ work interaction? . . . .
  • Are controls easy to reach from operators usual workplace location?
. . . .
  • Are foot controls suitable in position and size?
. . . .
  • Is the display/dial easy to read from operators usual workplace location?
. . . .
  • Can head and neck strain be avoided when reading displays?
. . . .
  • Are the operation of controls compatible with population stereotypes?
. . . .
  • Are labels on controls and dials clear?
. . . .
  • Are controls/dials labels adequately lit?
. . . .
  • Are there a manageable number of controls?
. . . .
  • Are all controls/dials/displays for similar functions grouped together?
. . . .
  • Are controls/dials/displays easy to distinguish from one workstation to another?
. . . .
  • Are hand/foot controls easy to use?
. . . .
  • Is the force required to operate hand/foot controls within a reasonable range?
. . . .
  • Is there a written operational procedure for use of controls/dials and displays?
. . . .
  • Is the information on display presented in a simple format?
. . . .
  • Does the display require only intermittent attention?
. . . .
  • Do employees need to deal with only a moderate amount of information?
. . . .
  • Do employees have adequate time to process information on display?
. . . .
  • Can employees deal with all the information provided on the display?
. . . .
  • Is it acceptable if control movements are inaccurate?
. . . .

4

WORK PRACTICES

Yes

N/A

No

Comments

4.1

Reaches
Does reach required optimise human/ work interaction? . . . .
  • Does task involve only a comfortable forward reach away from body?
. . . .
  • Is extended reach minimised, especially where reaching is held for a long duration, is repetitive or requires trunk/ torso deviations?
. . . .

4.2

Clearances
Do clearances optimise human/ work interaction? . . . .
  • Is clearance sufficient to - operate controls?
  • - perform task?
  • - use equipment?
. . . .
  • Are clearances adequate to avoid contact with objects that have
  • - sharp edges?
  • - contain hot or cold materials?
  • - slippery materials/objects?
. . . .

4.4

Storage
Does storage optimise human/ work interaction? . . . .
  • Are heavy and frequently used items stored at waist height?
. . . .
  • Is suitable storage provided?
. . . .
  • Are shelves free of dust, rubbish and unused items?
. . . .
  • Is there adequate space for storage?
. . . .

4.5

Work Conditions
Do work conditions optimise human/ work interaction? . . . .
  • Are employees suitably clothed?
. . . .
  • Is adequate time allowed for task completion?
. . . .
  • Is there job rotation or substitution of tasks that require a different activity where posture, force and repetition hazards have not been adequately addressed by design?
. . . .
  • Is seating provided and satisfactory in design?
. . . .
  • Are convenient work surfaces available to support job documentation, instruction manuals etc?
. . . .
  • Are workers informed about process flow and output?
. . . .
  • Are QA procedures in place to evaluate work practices?
. . . .

5

PHYSICAL AND PSYCHOLOGICAL TASK DEMANDS

Yes

N/A

No

Comments

5.1

General Physical Task Demands
Do physical task demands optimise human/ work interaction? . . . .
  • Are the physical dimensions of the employees adequately considered?
. . . .
  • Can employees avoid sudden movements during manual handling?
. . . .
  • Are arm/wrist supports provided where appropriate?
. . . .
  • Can employees avoid machine pacing of manual handling tasks?
. . . .
  • Is frequent ladder climbing avoided?
. . . .
  • Do employees need to discriminate by touch?
. . . .

5.2

Lifting
Does task encourage lifting that optimises human/ work interaction? . . . .
  • Are loads handled (in a position other than sitting) less than 20kg?
. . . .
  • Are weights above 55kg avoided?
. . . .
  • Are objects lifted infrequently?
. . . .
  • Can a two person lift be utilised if required?
. . . .
  • Are staff available when performance of team lifts is required?
. . . .
  • Are lifting devices utilised optimally?
. . . .
  • Can unbalanced or uneven lifting be avoided?
. . . .

5.3

Carrying
Does task encourage carrying of loads that optimise human/ work interaction? . . . .
  • Are loads carried less than 5 metres?
. . . .
  • Can carrying of loads over long distances be avoided?
. . . .
  • Are assistive devices used when transporting loads?
. . . .
  • Can unbalanced or uneven carrying be avoided?
. . . .

5.4

Loads
Does task encourage handling of weights that optimise human/ work interaction? . . . .
  • Are lifts/carries near the floor, above shoulders or far in front of body avoided?
. . . .
  • Can handling oversized objects be avoided?
. . . .
  • Can constant handling of loads without a break be avoided?
. . . .
  • Can lifting objects with unstable/unbalanced contents be avoided?
. . . .
  • Can handling more than 4.5kg in a seated position be avoided?
. . . .
  • Is lifting/carrying when climbing ladders avoided?
. . . .

5.5

Movements
Do movements optimise human/ work interaction? . . . .
  • Are high precision movements avoided?
. . . .
  • Are repetitive movements avoided?
. . . .
  • Are tasks which require good balance skills avoided eg walking on beams?
. . . .

5.6

Postures
Does task performed allow for postures which optimise human/ work interaction? . . . .
  • Are comfortable postures encouraged when interacting with workstation/ equipment?
. . . .
  • Does task encourage employees to avoid stooping where the hands pass below mid thigh height?
. . . .
  • Does task encourage employees to avoid reaching above shoulder height when performing task?
. . . .
  • Can employees avoid asymmetrical loading when performing task?
. . . .
  • Does task encourage avoidance of unstable or rotational body postures?
. . . .
  • Does task encourage avoidance of significant sideways twisting of the body?
. . . .
  • Can employees vary posture frequently throughout the day when undertaking task?
. . . .
  • Can employees avoid sitting/standing for long periods of time when undertaking task?
. . . .
  • Can employees avoid exertion of forces in awkward postures eg. side, overhead or extended reaches when undertaking task?
. . . .
  • Do workstation design and job requirements avoid body positions being held for extended periods?
. . . .
  • When performing task is static muscle load avoided in:
  • hand?
  • arm/shoulder?
  • neck?
  • back?
  • legs?
. . . .
  • Does task allow smooth, controlled movements to be adopted?
. . . .
  • Does workplace layout permit satisfactory postures to be adopted?
. . . .
  • Does workplace layout permit satisfactory control over physical movements?
. . . .

5.7

Hand Grasp
Does hand grasp optimise human/ work interaction? . . . .
  • Is high pressure from thin edges avoided eg. pail handles, sheet metal edges?
. . . .
  • Is finger pinch grip avoided?
. . . .
  • Are awkward grips avoided?
. . . .

5.8

Psychological Task Demands
Do psychological task demands optimise human/ work interaction? . . . .
  • Is the task simple to perform?
. . . .
  • Does task avoid monitoring of multiple factors simultaneously?
. . . .
  • Are only low demands on psychological performance in short time frames required?
. . . .
  • Are employees required to concentrate for long periods of time?
. . . .
  • Is activity repetitive, monotonous or unvarying?
. . . .
  • Is there a back up system if a mistake is made?
. . . .
  • Are use of long digit codes avoided eg. greater than 8?
. . . .
  • Do employees have minimal demands on memory?
. . . .
  • Can employees avoid quick decision making?
. . . .
  • Is task sufficiently challenging?
. . . .
  • Is task too challenging?
. . . .
  • Have written instructions been provided and understood?
. . . .

6

ORGANISATIONAL ISSUES

Yes

N/A

No

Comments

6.1

 Do organisational issues optimise human/ work interaction? . . . .
  • Are supervisors able to assist with queries/ questions?
. . . .
  • Is the culture of the organisation desirable?
. . . .
  • Is there collaboration with all levels to complete task?
. . . .
  • Is positive feedback given relating to work completed?
. . . .
  • Is there cooperation of staff on same levels?
. . . .
  • Is there cooperation of staff on different levels within the organisation?
. . . .
  • Is morale adequate to complete task efficiently?
. . . .
  • Is pay an incentive to complete task efficiently and effectively?
. . . .
  • Are there incentives other than pay to complete tasks efficiently and effectively?
. . . .
  • Is a lunchroom provided?
. . . .
  • Are there official breaks?
. . . .
  • Are timing and length of breaks reasonable?
. . . .
  • Is there adequate provision of food and drink during breaks?
. . . .
  • Does task allow social contact?
. . . .
  • Are there shorter shifts on night shift?
. . . .
  • Do employees have a choice in timing of rosters/ shifts?
. . . .

7

EMPLOYEE CHARACTERISTICS

Yes

N/A

No

Comments

7.1
  • Is employee(s) responsible for completing task, new to the organisation or returning from an extended period of leave?
. . . .
  • Do employee(s) responsible for completing the task have age related characteristics, disabilities and/ or other special characteristics that may affect task performance?
. . . .
  • Are employees required to judge distances carefully eg. using high stacking capability on a forklift truck?
. . . .
  • Are staff competent at tasks performed?
. . . .
  • Are staff aware of correct lifting, standing and sitting postures?
. . . .
  • Do employees have good vision?
  • Are staff trained for work performed?
. . . .
  • Is skill required within employees level of expertise?
. . . .
  • Is completion of tasks suited to the physical capacity of the individual performing the task?
. . . .

SAFETY ISSUES NOT INCLUDED

Yes / No

S.1

Personal Protective Equipment

Is the following PPE required:

  • Hard hat?
.
  • Gloves?
.
  • Footwear?
.
  • Overalls?
.
  • Eye protection?
.
  • Ear Protection?
.
  • Dust masks?
.
  • Are workers suitably clothed?
.
  • Are the supply of liquids sufficient?
.
  • Can radiant heat be reduced by protective devices?
.
  • Does clothing interfere with task performance?
.
  • Are employees instructed in the use of PPE?
.
  • Is PPE worn when necessary?
.
  • Is there a regular maintenance programme for PPE?
.
  • Is there an OSH committee?
.
  • Are you aware of who your OSH representative is?
.
  • Do receive communication from OSH representative or committee?
.
  • Did you undergo a training or induction programme?
.
  • Does your company have a OSH policy?
.
  • Are safety signs located in strategic positions to alert to hazards?
.

S.2

Electricity
  • Are wet locations mopped up or prevented especially when using power tools?
.
  • Are correct ladders used when performing electrical tasks?
.

S.3

General
  • Are substances which may cause dermatitis avoided?
.
  • Is the risk of burns or explosions avoided?
.
  • Are danger tags available?
.
  • Are lock switches provided?
.

S.4

Safety Features
  • Are fire alarms functioning?
.
  • Are exits clearly marked and accessible?
.
  • Are correct fire extinguishers available?
.
  • Are gas cylinders stored securely?
.
  • Are staff trained/ qualified to use equipment?
.
  • Are staff aware/ trained in emergency procedures?
.
  • Is regular maintenance on machinery/ hand tools carried out?
.
  • Are safety signs are located in strategic positions to alert to hazards?
.