Ergonomics Sheet PDF

Review questions in Environmental and safety factors 1. What are the key environmental factors that can affect worker safety in a factory setting? Key factors include: o Lighting: Lux levels between 300–500 lux for general tasks; up to 1000 lux for precision task...

Review questions in Environmental and safety factors 1. What are the key environmental factors that can affect worker safety in a factory setting? Key factors include: o Lighting: Lux levels between 300–500 lux for general tasks; up to 1000 lux for precision tasks. o Noise: OSHA’s permissible exposure limit is 85 dB over an 8-hour workday. o Temperature: Comfortable range is 20–24°C (68–75°F). o Air Quality: Carbon dioxide levels should not exceed 1000 ppm. 2. Why is proper ventilation important in factories? Ventilation ensures that harmful airborne contaminants remain below the Threshold Limit Values (TLVs) set by organizations like ACGIH. Adequate air exchanges (6–12 times per hour) maintain air quality. 3. What role does lighting play in ensuring worker safety in a factory? Proper lighting ensures visibility, reduces accident risks, and minimizes eye strain. Standard lux levels are: o General work: 300–500 lux. o Fine detail work: 1000 lux or more. 4. How can noise levels in factories impact worker health and productivity? Noise above 85 dB (decibels) can cause hearing loss over time. For noise over 100 dB, exposure should be limited to less than 15 minutes per day without hearing protection. Chronic noise can also lead to stress and reduced focus. Conceptual Questions 5. How does temperature and humidity influence worker performance and safety in factories?  o Temperature:  Comfortable range: 20–24°C (68–75°F).  For heavy physical work, lower temperatures (16– 20°C) are preferred. o Humidity:  Recommended levels: 40–60%. High humidity can lead to heat stress, while low humidity increases dehydration risks. 6. What are common safety hazards found in factories, and how can they be addressed? Common hazards include: o Slips and falls: Use anti-slip flooring and clean spills immediately. o Machinery accidents: Ensure all equipment has proper guards and emergency stops. o Chemical exposure: Follow OSHA's PEL (Permissible Exposure Limits) for toxic substances. 7. Why is it important to design factory layouts with ergonomic principles in mind? Ergonomic designs reduce repetitive strain injuries and improve productivity. For example: o Ensure workstations allow for neutral postures, keeping wrists straight and shoulders relaxed. o Limit repetitive tasks to ≤30 repetitions per minute for hand-intensive work. 8. How can air quality issues in factories be mitigated to improve worker safety? o Use exhaust systems to keep airborne particles like dust and fumes below TLVs. o Carbon monoxide should not exceed 50 ppm, and particulate matter (PM2.5) should remain below 12 µg/m³. Application Questions 9. Imagine you are tasked with improving the lighting in a factory. What changes would you suggest to reduce eye strain and accidents? o Install LED lights with brightness levels of 300–500 lux for general work and 1000 lux for fine detail tasks. o Use anti-glare screens and ensure light is evenly distributed across workspaces. 10. A factory has high noise levels due to heavy machinery. What solutions would you propose to protect workers from hearing damage? o Install soundproof barriers and enclosures for noisy machinery. o Use PPE like earplugs or earmuffs with a Noise Reduction Rating (NRR) of at least 25 dB. o Ensure compliance with OSHA's noise standards: 85 dB for an 8-hour shift, reducing allowable time by half for every 5 dB increase. 11. Design an emergency evacuation plan for a factory. What factors would you consider to ensure worker safety? o Emergency exit doors must comply with OSHA standards:  At least 28 inches wide.  Clearly marked and unobstructed. o Evacuation time should ideally be less than 4 minutes for large facilities. o Emergency lighting must provide at least 1 lux of illumination. 12. How would you assess whether a workstation in a factory is ergonomically safe? o Monitor work height: Standing tasks should place the work surface at 2–4 inches below elbow height. o Check repetitive tasks: Aim for fewer than 10,000 repetitions per 8-hour shift for hand-intensive tasks. o Evaluate posture: Ensure no extreme wrist bending (keep wrists within 15° neutral range). Critical Thinking Questions 13. What are the potential consequences of ignoring environmental and safety factors in a factory? o Higher injury rates, e.g., MSDs, slips, and falls. o Fines for regulatory non-compliance, e.g., OSHA penalties of up to $15,625 per violation. o Loss of productivity due to absenteeism and lower morale. 14. How can factories balance the need for production efficiency with the implementation of safety measures? o Automate hazardous tasks using robotics or AI systems. o Provide training to maximize productivity within safe work limits, e.g., lifting limits below 50 lbs for repetitive tasks. 15. Discuss the challenges of introducing safety protocols in older factories versus newly built ones. o Older factories often require costly retrofits to meet modern safety standards. For example, older equipment might lack proper machine guards or emergency stops. o New factories can incorporate modern safety designs such as height-adjustable workstations and sensor-based hazard monitoring. 16. How could advances in technology (e.g., automation, sensors) help improve safety in factories? o Sensors can monitor real-time air quality, noise, and temperature, alerting workers when thresholds are exceeded. o Automated systems can reduce human interaction with hazardous tasks, e.g., robotic arms for heavy lifting above 50 lbs. Scenario-Based Questions 17. A factory worker complains of frequent headaches and fatigue while working. What environmental factors might you investigate to identify the cause? o Lighting: Ensure levels are within the 300–500 lux range for general tasks. o Air quality: Measure CO2 (target