1. ASEP Ergonomic support development Fall 2002 Arm Supports for Ergonomic Positioning EH&SEETDEngineering Division++ TEAM: Jeff Chung, Michael Siminovitch, Robin Lafever, Steve Dellinges

2. ASEP Ergonomic support development Fall 2002 The Need... “Scientific evidence shows that musculoskeletal disorders of the lower back and upper extremities can be attributed to particular jobs and working conditions – including heavy lifting, repetitive and forceful motions, and stressful work environments…but the problem can be reduced with well-designed intervention programs.” National Academy of Sciences Report (1/18/2001) FY 99: 43% of all disabling workplace injuries and illnesses (nation-wide) are associated with ergonomics and at a financial cost of $16.8 billion. [Liberty Mutual Workplace Safety Index Report – 2002] FY 02: 62% LBNL DOE-Recordable cases caused by poor ergonomics (Strains/Sprains, CTDs & RSIs). FY 02: LBNL Property Management dBase inventoried > 9,400 computers (desktops and laptops) issued to employees. 7/99-8/02: 20% LBNL employee visits (168) to Health Services triggered by computer use. 4/85-6/02: 145 WComp “ergo claims” resulting > $2M incurred costs and 13,602 days of TD/Loss Work Days (productivity).

3. ASEP Ergonomic support development Fall 2002 Idea Engineering Concepts Lab set up Concept generation Hardware Fab, Mod, Iterate Testing and Evaluation Screen candidates Invention Disclosure Engineering Development LBNL Technology Transfer Acquire instrumentation Measure Muscle Activity Refine Evaluation Criteria Develop Engineering Prototypes Conduct Engineering tests $ $ Industry Solution Development Funding LBL Presentation McGraw Presentation Seed money $ Production Prototype Funding $ Industry CRADA or SBIR Product Development Phase IPhase IIPhase III Develop Product requirements Design for manufacture Produce production prototypes Conduct product field testing We are Here ! Commercialization

4. ASEP Ergonomic support development Fall 2002 Phase I, Design Effort

5. ASEP Ergonomic support development Fall 2002 Office Environment – Computer work Manufacturing Environment – Light Assembly Lab Environment – Repetitive Handwork Inspection Fume Hoods Biological Safety Cabinets Production Genomics Work Life Sciences Benchwork Applications

6. ASEP Ergonomic support development Fall 2002 Phase II Mechanical Arm Rest Development Engineering Models Several prototypes Test results to Iteration CAD models & Drawings Analysis / Animations Shop work & Assembly + materials Production package CAD models & Drawings Exemplar Shop Visits Short-run production Lab Testing Lab / Equipment set-up Train crew Perform testing Reduce results Industry Presentation Documentation Slide show Improve existing prototypes Misc. tweaks and improvements Add roller bearings Address safety issues Set-up in lab environment Shop work & Assembly + materials 6 Month Plan - $150k Cycles through engineering models.

7. ASEP Ergonomic support development Fall 2002 R&D Ergonomics Applications – Benefits Management of Business Productivity: science and operations Asset Protection and Preservation: human, physical and intellectual DOE Mission Success: multi-program and interdisciplinary R&D CRADA: collaboration, innovation and industry partnerships Recognition: engineering and safety excellence (nationally and internationally) Team R&D Team Funding

8. ASEP Ergonomic support development Fall 2002 Commercial Devices

9. ASEP Ergonomic support development Fall 2002 The plan The overall plan is to study, design, and develop practical ergonomic support devices. Refine appropriate designs into applied solutions of interest to Manufacturers. –Use LBNL/Engineering skills and expertise to provide public benefit in an area that is ubiquitous and in need of significant improvement. –Offer good potential for commercialization & subsequent income stream to LBNL. –Address area of interest to all parties involved: DesignWorks, EH&S, EETD, LBL. Conduct a 3 phase program : –Phase 1 Set up lab and test facilities Generate concepts, Fabricate Prototypes Fabricate, test, and screen proposed solutions –Phase 2 Acquire instrumentation Refine evaluation criteria Measure muscle activity Develop Engineering prototypes Conduct quantitative evaluation –Phase 3 Develop Product requirements Design for manufacture Produce production prototypes Conduct product field testing

10. ASEP Ergonomic support development Fall 2002 Phase I Activities Lab set up Dedicated Lab space in DesignWorks development Laboratory (77-244) Basic ‘Tool-up’ including Tool kits, Shop equipment, and Materials. Concept generation Early on, the team adopted a structured iteration cycle to accelerate the development process. Access to and use of the DesignWorks ‘Brainstorming’ team establishes a range of options. Sketches, crude mock-ups, hand-calculations, approximate measurements refine options. Next Concept based on tested results in real-time and is realized in hardware. Hardware Hardware focused on applying load points to the human arm and shoulder. With appropriate fixtures we can both apply and measure forces and vectors between points. Body supported systems Device reroutes forces from one part of the anatomy to another. External support systems Device absorbs or applies forces to the anatomy. Testing and Evaluation Mechanical measurements and temporary test set ups set practical range of forces for prototypes. Human try-outs brought sharp focus to iterations of practical mechanical fixtures and prototypes.

11. ASEP Ergonomic support development Fall 2002 Phase I Concepts External support systems Device absorbs or applies forces to the anatomy externally. The effective dynamic is to provide a lifting force, or net decrease in gravity, applied to selected parts of the arm-shoulder system. Reactions and redistributed forces are routed to the chair, or floor. Body supported systems Device reroutes forces from one part of the anatomy to another. The effective dynamic is to augment or unload muscle groups that ordinarily take constant strain, and reroute forces onto other parts of the anatomy, into the chair, or into the floor.

12. ASEP Ergonomic support development Fall 2002 Body SupportedExternally Supported  Add Seamstress  Iterate Design  Create One-Off Prototypes  Preliminary Ergonomic Testing CYCLE Create Prototype Design Package Photos Patterns Materials Short-Run Production ( 1 to 3 units) Presentation for CRADA CYCLE Rework Existing Prototypes for lab testing  Test current hardware  Iterate Design / CAD / Drawings  Create One-Off Prototypes  Preliminary Ergonomic Testing Create Prototype Design Package CAD Shop work Assembly Short-Run Production ( 1 to 3 units) Presentation for CRADA Phase II, Engineering Effort

13. ASEP Ergonomic support development Fall 2002 Iteration to design package Several prototypes Test results to Iteration CAD models & Drawings Production package CAD models & Drawings Exemplar Shop Visits Short-run production Lab Testing Lab / Equipment set-up Train crew Perform testing Reduce results Industry Presentation Documentation Slide show Phase II Body Supported Device Development 4 Month Plan Cycles through iteration.

14. ASEP Ergonomic support development Fall 2002 Phase II Body Supported Device Development w/FTE Who: 2-FTE, 1-Seamstress Iteration to design package Several prototypes Test results to Iteration CAD models & Drawings Production package CAD models & Drawings Exemplar Shop Visits Short-run production Lab Testing Lab / Equipment set-up Train crew Perform testing Reduce results Industry Presentation Documentation Slide show FTE (WEEKS) 4 4 2 1 4 TOTAL15 Cycles through iteration.

15. ASEP Ergonomic support development Fall 2002 Who: 3-FTE Engineering Models Several prototypes Test results to Iteration CAD models & Drawings Analysis / Animations Shop work & Assembly + materials Production package CAD models & Drawings Exemplar Shop Visits Short-run production Lab Testing Lab / Equipment set-up Train crew Perform testing Reduce results Industry Presentation Documentation Slide show FTE (WEEKS) 2 8 3 3 4 Improve existing prototypes Misc. tweaks and improvements Add roller bearings Address safety issues Set-up in lab environment 2 Shop work & Assembly + materials Phase II Mechanical Arm Rest Development w/FTE TOTAL22 Cycles through engineering models.

16. ASEP Ergonomic support development Fall 2002 Experimental Design UPPER EXTREMITY POSTURES: STATIC AND DYNAMIC CONDITIONS Measurements (Standing and Sitting) Neutral Position, Self-Supporting - Stationary Neutral Position, Self Supported - Working w/in ROM Non-Neutral Position, Self Supported – Working Outside ROM Elbow Joint Angle (degrees) EMG Activity (mV): various muscle groups Normal Force (lbs) Measurements (Standing and Sitting) Neutral Position, Shawl Device Supported - Stationary Neutral Position, Shawl Device Supported - Working w/in ROM Neutral Position, Shawl Device Supported - Working Outside ROM Elbow Joint Angle (degrees) EMG Activity (mV): various muscle groups Normal Force (lbs) Measurements (Standing and Sitting) Neutral Position, External Device Supported - Stationary Neutral Position, External Device Supported - Working w/in ROM Neutral Position, External Device Supported - Working Outside ROM Elbow Joint Angle (degrees) EMG Activity (mV): various muscle groups Normal Force (lbs)