1. 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 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).

2. ASEP Ergonomic support development Fall 2002 The Flow Idea Engineering Studies Lab set up Concept generation Hardware Fab, Mod, Iterate Testing and Evaluation Screen candidates Invention disclosure Engineering development LBNL Technology Transfer Commercialization Acquire instrumentation Refine Evaluation Criteria Develop Engineering Prototypes Conduct Engineering tests Conduct Human tests Field Test $ $ 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 testing We are Here !

3. ASEP Ergonomic support development Fall 2002 The plan The overall plan is to study, design, and develop practical ergonomic support devices. And to 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. Develop Engineering prototypes. Conduct quantitative evaluation and Human tests. Field test –Phase 3 Develop Product requirements Design for manufacture Produce production prototypes Conduct product testing

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

5. ASEP Ergonomic support development Fall 2002 Phase I Studies Lab set up Dedicated Lab space in DesignWorks development Laboratory (77-2xx) Basic ‘Tool-up’ including Tool kits, Shop equipment, and Software. 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 { Pictures, lists } 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 and fixtures { Pictures, lists } Human try-outs brought sharp focus to iterations of practical mechanical fixtures and prototypes

6. 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.

7. ASEP Ergonomic support development Fall 2002 SHAWL CHAIR  Add Seamstress  Iterate Design  Create One-Off Prototypes  Preliminary Ergonomic Testing CYCLE Create Prototype Design Package Photos Patterns Materials Short-Run Production ( 5 to 10 units) Field Testing 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 ( 5 to 10 units) Field Testing Presentation for CRADA Phase II, Engineering Effort

8. ASEP Ergonomic support development Fall 2002 SHAWL DETAIL 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 Cycles through iteration. Field Testing Perform testing Reduce results Presentation Documentation Slide show FTE (WEEKS) 4 4 2? 1 4 Phase II Shawl Development

9. 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 Production package CAD models & Drawings Exemplar Shop Visits Short-run production Lab Testing Lab / Equipment set-up Train crew Perform testing Reduce results Cycles through Engineering Models Field Testing Perform testing Reduce results Presentation Documentation Slide show FTE (WEEKS) 2 8 2 2? 4 Improve existing prototypes Misc. tweaks and improvements Add roller bearings Address safety issues Set-up in lab environment 2 Shop work & Assembly Phase II Chair Development

10. ASEP Ergonomic support development Fall 2002 Office Environment – Computer work (photo) Manufacturing Environment – Light Assembly (photo) Lab Environment – Repetitive Handwork (photo) Construction Environment Artistic Musicians Drafting Layout Inspection Applications