OEL REPORT

Human Factor Engineering

Title:
Evaluation of working posture and surrounding environment
using assessment tool in cable and wire manufacturing industry

December 12th, 2024

Submitted To :

Dr. Faisal Shehzad

Submitted By :

Registration number Work Contribution

2022-IM-29 Report Making+ Data Collection +Workshop visit

2022-IM-22 Rula & Reba Assessment

2022-IM-03 Literature review + Report Making

2023R/2022-IM-27 FMEA + FTA Assessment

 Human Factor Engineering

Table of Contents
Table of figures: ................................................................................................................................ 1
Course learning outcomes: ............................................................................................................ 2
Literature review: .......................................................................................................................... 2
Human factor engineering: ........................................................................................................ 2
Objectives of human factor engineering: ................................................................................... 2
Implication of human factors in industrial engineering design:................................................... 2
Working posture assessment tools: ............................................................................................ 3
Industry related literature review: .................................................................................................. 4
Manufacturing process of electric wire cables: .......................................................................... 4
Flow chart of processes: ............................................................................................................ 4
Selection of industry: .................................................................................................................. 18
General view of work in industry:................................................................................................ 18
Industry culture and workers experience level: ............................................................................ 18
Fresh workers: ........................................................................................................................ 19
Intermediate experienced workers: .......................................................................................... 19
Highly experienced workers : .................................................................................................. 19
How to look for ergonomics hazards in industry: ......................................................................... 19
Framework of industry visit:........................................................................................................ 19
Hazards in industry: .................................................................................................................... 19
Hazard categories excel sheet: ......................................................................................................... 20
References:...................................................................................................................................... 24

Table of figures:

Figure 1:Types of Electric cables ....................................................................................................... 4

Figure 2: Crushing of metal ............................................................................................................... 5
Figure 3: Drawing machine ............................................................................................................... 8
Figure 4: Heating/Annealing of metals............................................................................................. 10
Figure 5: Insulation of wires ............................................................................................................ 12
Figure 6: Twisting of wires .............................................................................................................. 13
Figure 7: Cable extrusion machine ................................................................................................... 15
Figure 8: Cutting of cables ............................................................................................................... 16

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Course learning outcomes:

1. Analyze the existing workplace in the light of human factor engineering for potential
improvement in workplace. (CLO3 & PLO3)
2. Demonstrate literature review and skills to supplement course project. (CLO4 & PLO11)

Literature review:
As the problem statement of our open ended lab requires us to evaluate working posture,
surrounding environment and human factor engineering principle and worker situation within
context of human factor engineering for chronic and acute problem and their remedies must be
clear to us.

Human factor Engineering:

Human factors focus on human beings and their interaction with machines, material and,
procedures and environments used in work and everyday living. Human factors discover and
applies information about human behavior, capabilities, limitations, and other characteristics to
the design of products machines systems, tasks, jobs, and work-environments for productive, safe,
comfortable, and effective human use. The International Labor organization (ILO) has defined
the term ‘Human Factors’ as “the application of human biological sciences in conjunction
with engineering sciences to the worker and his work environment, so as to obtain
maximum job satisfaction, which at the same time enhances productivity”. Human factors
engineering is the science of fitting the job to the worker. In a phrase, the task/ job must ‘fit the
person’ in all respects, and the work situation and [1]

Objectives of human factor engineering:

Human factors engineering has two major objectives. The first is to enhance the effectiveness and
efficiency with which work and other activities are carried out. This includes such things as
increased convenience of use, reduced errors and increased productivity. The second objective is
to enhance certain desirable human values, including improved safety, reduced fatigue and stress,
increased comfort, greater user acceptance, increased job satisfaction, and improved quality of
life. To develop the optimal conditions for the workers in work environment, to reduce
physiological costs. [1]

Implication of human factors in industrial engineering design:

Human factor has a wide application in everyday living and domestic situations, however there
are even more significant implications for efficiency, productivity, safety, health, and comfort in
work settings. Among the many important roles identified, human factors engineering plays the
following basic functional roles:
•Methods and operation design
•System and interface design
•Product and equipment design
•Task and job design
•Workstation, work arrangement and working environment design
•Information design [1]

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Working posture assessment tools:

There are various tools are available for the assessment of human body and ergonomics factors when
exposed to work. These tools explained the severity of working environment. These tools evaluate the
whole body when exposed to work and tools include RULA, REBA and NIOSH LIFTING
EQUATION.

RULA:
Rapid Upper Limb Assessment (RULA) is a survey method developed for use in ergonomic
investigations of workplaces where work related upper limb disorders are reported. RULA is a
screening tool that assesses biomechanical and postural loading on the whole body with particular
attention to the neck, trunk and upper limbs. Reliability studies have been conducted using RULA on
groups of users and sewing machine operators. A RULA assessment requires little time to complete
and the scoring generates an action list which indicated the level of intervention required to reduce the
risks of injury due to physical loading on the operator. RULA is intended to be used as part of a
broader ergonomic study. [2]

REBA:
The Rapid Entire Body Assessment (REBA) is one of the commonly used survey methods for
analyzing working postures to minimize injury and support employee health. This comprehensive
guide will outline the REBA process for evaluating biomechanical and postural risks, scoring and
ranking different levels of risk. With the proper use of the REBA tool, companies can avoid
unnecessary strain on workers while increasing engagement and retention. [3]

NIOSH LIFTING EQUATION:

The Revised Lifting Equation (RNLE) is a tool to calculate risk for work-related musculoskeletal
disorders (WMSDs). The equation can be used to calculate both single and multiple manual lifting
tasks. Using the equation can reduce the incidence of low back injuries in workers.
NIOSH created the RNLE because many workers are responsible for manually lifting and moving
objects on the job. These workers are in numerous occupations and industries. Exposure to repetitive
lifting puts workers at risk for developing WMSDs. Understanding how much workers can safely lift
is important to preventing those injuries. [4]

Why selecting cable and wires manufacturing industry:

Cables and wire manufacturing industry is selected due to various process involved in the
manufacturing of wires and then wires into cables and then evaluate how human factor engineering
can change this environment. These steps include crushing and grinding in which metals like copper
and aluminum crushed at first step to get to manufacture wires and to extracted metals and then small
pellets of plastic material is crushed and when these pellets crushed some of their particles mixes with
air and diffused into worker lungs when they breathe. This process can damage workers health and
can cause chronic respiratory disorders. In conclude to this human factor engineer can give solution of
this problem. Second process of this manufacturing is drawing in which manual handling drawing is
observed in various industries of Pakistan. When manual handling is performed it may damage the
hand of worker and working posture of worker and these develops the risk of MSD disorders. Huma
factor engineer provide solution of this problem. Third step includes heating which release dangerous
particles which cause respiratory disorder. Human factor engineer can give solution to this problem.
Fourth step includes insulation in which the plastic pellets liquidous form insulate on the cable wires
it may burnt the hands of operators when safety parameters not used. Then twisting and extrusion
process is done which involves repetitive motion, long hours of working and work stress. HFE

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engineer can solve this problem. Last cutting is done manually which damage the workers hands if
safety parameters not applied so the purpose of selecting this industry to evaluate the risk related to
HFE principle and to increase the production of industry.

Industry related literature review:

To evaluate the working postures of workers and human factor engineering principle in workplace,
first we have to know about the process taking place in that particular workplace or industry.

Manufacturing process of electric wire cables:

Lets explore the manufacturing process of cables and wires.

FIGURE 1:TYPES OF ELECTRIC CABLES

Flow chart of processes:

Crushing
and Insulatio Cutting
grinding Drawing Heating Twisting Extrusion
n

1. Crushing and Grinding:

The metals like Copper and Aluminum are crushed at the first step to manufacture wires. The process
of crushing and grinding is done in large machines. With this process, the squandered material is

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removed and the metal is extracted. Then the plastic pellets crushed to get the liquidous form for the
coating of metal wires. [5]

FIGURE 2: CRUSHING OF METAL

Figure 3: Carrying PVC pallets for crushing process (for REBA analysis)

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REBA Assessment of this process:

Task Neck Trunk Leg Upper Lower Wrist Activity REBA Risk
score score score arm arm score score final level
score score score
Manual +2 +4 +3 +3 +2 +3 +2 12 Very
carrying high
load

REBA-Based Manual Handling Recommendations:

1. Limit load weight to safe, manageable limits.
2. Use proper lifting techniques to protect the spine and reduce strain.
3. Avoid twisting or awkward postures while carrying.
4. Minimize carrying distance and use aids for longer distances.
5. Ensure a secure grip by using handles or enhancing the grip surface.
6. Prepare the environment to prevent slips, trips, and falls.
7. Incorporate rest breaks or task rotation to reduce repetitive strain.
8. Use team lifting for heavier or awkward loads.

Implementing these guidelines will help minimize the ergonomic risks of manual handling and align
with REBA's recommendations to reduce the likelihood of musculoskeletal injuries.

Figure 4: Working posture during crushing (for RULA analysis)

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RULA Assessment of working posture:

Task Upper Lower Wrist Neck Trunk Leg Muscle Force RULA
arm arm score score score score used /load final
score score score
Manual +5 +2 +3 +5 +1 +2 +1 +2 +7
Handling/
lifting
task

Risk level: Very High

RULA-Based Recommendations for Manual Load Carrying:

a) Maintain a neutral posture and avoid twisting or bending the spine.
b) Hold loads close to the body to reduce shoulder and back strain.
c) Limit load weight and use mechanical aids when necessary.
d) Avoid awkward movements like reaching, bending, or twisting.
e) Use handles or ergonomic grips to reduce wrist and hand strain.
f) Take breaks and rotate tasks to reduce cumulative strain.
g) Engage core and leg muscles when lifting or carrying.
h) Use team lifting for heavy or large loads.
i) Organize workstations to minimize high or low lifting.
Implementing these RULA-based recommendations can significantly reduce upper body strain,
minimize the risk of musculoskeletal injuries, and improve the ergonomic safety of manual load-
carrying tasks in the workplace.

Hazards and their recommendation during crushing and grinding process:

Grinding in the cable industry can present several hazards to workers. These include physical,
chemical, and ergonomic hazards due to the nature of grinding processes, materials used, and the
machinery involved. Below are common hazards associated with grinding in the cable industry and
recommended safety measures:

Hazard:
 Flying Debris and Particles: Grinding generates sparks, dust, and flying metal or cable
debris that can injure eyes and exposed skin.
Recommendation:
a) Provide and enforce the use of personal protective equipment (PPE) like safety
goggles, face shields, and gloves.
b) Install machine guards to contain flying particles.
c) Maintain work areas with adequate shielding and barriers to prevent particle travel.
Hazard:
 Respiratory Risks from Dust and Fumes: Grinding can release hazardous dust and
fumes, especially when working with certain metals or cable insulation materials.

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Recommendation:
1. Install proper ventilation systems, including local exhaust ventilation, to capture dust
and fumes at the source.
2. Provide respirators to workers if adequate ventilation cannot be achieved.
3. Regularly monitor air quality and conduct health surveillance for workers.
Hazard:
1. Noise Exposure: Grinding machines produce high levels of noise, which can lead to
hearing damage over time.
Recommendation:
2. Conduct regular noise assessments and reduce noise levels through engineering controls
like sound-dampening materials.
3. Require workers to use ear protection, such as earplugs or earmuffs, if noise cannot be
sufficiently reduced.
4. Limit exposure time in high-noise areas and ensure quiet rest zones are available.

2. Drawing:
Drawing wire is the next step in the manufacturing process. Material is drawn to produce different
gauge wires. In this process, engineers use many days to reduce the copper size. They also use copper
wire drawing lubricants for increasing the life of the day. After the successful process of wire
drawing, the wire becomes thin and malleable. [5]

FIGURE 5: DRAWING MACHINE

The drawing process in cable manufacturing, which involves pulling metal through dies to create wire
of specific dimensions, presents several hazards. These include physical, chemical, and ergonomic
risks due to high-tension equipment, exposure to lubricants, and repetitive motions. Here are common
hazards associated with the drawing process and recommended safety measures:

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Hazard:
Machine Entanglement and Contact with Moving Parts: The drawing machines operate at high
speeds, and the moving parts, like pulleys, dies, and reels, pose a risk of entanglement and injury.

Recommendations:
1. Ensure all machine parts are equipped with guards and barriers to prevent accidental
contact.
2. Train workers on the risks of loose clothing, jewelry, and long hair near drawing
machinery.
3. Implement and enforce lockout/tagout (LOTO) procedures during maintenance to
prevent accidental start-up.
Hazard:
Chemical Exposure from Lubricants: Lubricants are used to reduce friction and wear during drawing,
but they can contain chemicals harmful if inhaled or in contact with skin.

Recommendations:
1. Provide adequate ventilation to prevent the buildup of fumes in the work area.
2. Use PPE such as gloves, long sleeves, and eye protection to prevent skin and eye
contact with lubricants.
3. Train workers on safe handling of lubricants, including proper storage and disposal
practices.

Hazard:
Noise Exposure: Drawing machines generate high noise levels, which can cause hearing loss over
time.

Recommendations:
1. Conduct noise assessments and use engineering controls, like sound-dampening
enclosures, to reduce noise at the source.
2. Require workers to wear hearing protection, such as earplugs or earmuffs, if noise
levels cannot be sufficiently controlled.
3. Limit workers’ exposure time in high-noise areas and rotate shifts if necessary.

Hazard:
Risk of Physical Injuries from Tension and High Forces: The drawing process involves high tension
and force to pull metal through dies, creating a risk of injury from snapped wire or machinery failure.

Recommendations:
1. Regularly inspect and maintain machinery to ensure it operates within safe tension
limits.
2. Use high-tensile protective barriers around drawing equipment to protect workers from
snapping wires.
3. Train workers on emergency stop procedures and provide clear emergency access
routes.

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Hazard:
Ergonomic Strain and Repetitive Motion Injuries: Workers may experience repetitive strain from
handling materials, bending, and lifting during the setup and removal of wire reels.

Recommendations:
a) Ensure workstations are ergonomically designed to minimize bending and awkward
postures.
b) Use mechanical aids such as hoists or reels to reduce manual handling of heavy
materials.
c) Rotate tasks among workers to prevent repetitive strain injuries.

3. Heating:
The process of gradually cooling metals to alleviate internal stresses and fortify them is known as
annealing. In wire and cable manufacturing, heat treatment is employed to soften wires. By subjecting
a metal rod to immense pressure, it's shaped into a thinner wire. The primary aim of heating during
annealing is to prevent cable oxidation. [5]

FIGURE 6: HEATING/ANNEALING OF METALS

The heating process in cable manufacturing, often used for insulation and curing or annealing metal
wires, presents a range of hazards. These include risks related to high temperatures, chemical
emissions, and equipment handling. Here are the common hazards associated with heating in cable
manufacturing and recommended safety practices:

Hazard:
Thermal Burns from High Temperatures: The heating process involves exposure to high
temperatures, which can cause severe burns upon contact with heated equipment or materials.

Recommendations:
1. Enclose or guard heated surfaces to prevent accidental contact.
2. Require workers to wear heat-resistant gloves, aprons, and other protective clothing.

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3. Post warning signs around high-temperature zones and ensure only authorized
personnel are allowed near active heating equipment.

Hazard:
Fire and Explosion Risks: The heating process can ignite flammable materials, such as cable
insulation, lubricants, or other production materials, increasing fire and explosion risk.

Recommendations:
1. Keep flammable substances away from heating equipment and storage areas.
2. Install fire extinguishers and automatic fire suppression systems in key locations.
3. Train workers in fire response procedures and conduct regular fire drills to ensure
readiness.

Hazard:
Chemical Exposure from Emissions and Fumes: Heating certain materials, especially plastics and
coatings, can release hazardous fumes and gases that may be toxic or irritant when inhaled.

Recommendations:
1. Use proper ventilation systems, such as local exhaust ventilation, to capture and
remove fumes at the source.
2. Provide respirators and ensure that all workers in areas with fume exposure are
trained in their use.
3. Conduct regular air quality monitoring to assess and control exposure to hazardous
chemicals.

4. Insulation:
Cables consist of various wires bundled together within an insulating material. Wires are
coated/cabled with PVC, PP or PE. Certain cables might require added elements for enhanced
protection. Engineers evaluate insulation materials based on their capacity and resistance to heat,
selecting them according to cable specifications. [5]

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FIGURE7: INSULATION OF WIRES

The insulation process in cable manufacturing, which involves coating metal conductors with
insulating materials (often polymers or rubber), presents a variety of hazards. These hazards stem
from high temperatures, chemical exposure, and the use of complex machinery. Below are common
hazards and recommended safety measures to mitigate risks during the insulation process:
Hazard:
Chemical Exposure to Insulation Materials and Additives: Insulating materials, such as PVC,
polyethylene, or rubber, and their additives can release toxic fumes or dust during processing, which
may pose respiratory and skin hazards.

Recommendations:
1. Use proper ventilation systems, including local exhaust ventilation, to capture and remove
fumes at the source.
2. Provide workers with PPE, such as gloves, long-sleeve clothing, and respirators when
handling insulation materials.
3. Regularly monitor air quality for harmful chemical levels and conduct health surveillance
for workers handling chemicals.

Hazard:
Thermal Burns from Hot Equipment and Materials: The extrusion machines and other equipment
used for insulation often operate at high temperatures, posing a risk of burns if workers accidentally
touch hot surfaces or materials.

Recommendations:
1. Equip hot surfaces and equipment with barriers or guards to prevent accidental
contact.
2. Provide workers with heat-resistant gloves and protective clothing.
3. Post warning signs near high-temperature equipment and conduct regular training on
thermal safety practices.

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Hazard:
Fire and Explosion Risks from Flammable Insulation Materials: Certain insulation materials or
additives are flammable, and improper handling can lead to fire or explosion, especially near heating
elements.

Recommendations:
1. Store flammable materials away from heat sources and in well-ventilated areas.
2. Install fire extinguishers and ensure workers are trained in fire response procedures.
3. Use spark-proof and non-combustible tools around insulation areas and avoid static
buildup.

5. Twisting and Stranding:

Multiple wires are often twisted together to boost flexibility and electrical performance compared to a
single wire. Manufacturers utilize specific machinery to efficiently carry out this process. [5]

FIGURE 8: TWISTING OF WIRES

The twisting and stranding process in cable manufacturing involves combining multiple wires or
strands to form a cable, which requires specialized machinery and techniques. This process can
present various hazards, including mechanical, ergonomic, and safety risks. Here are common hazards
and safety recommendations for the twisting and stranding process in cable manufacturing:

Hazard:
Mechanical Injuries from Moving Parts: Twisting and stranding machines have fast-moving parts,
including spools, bobbins, and rollers. These moving parts pose a risk of entanglement, pinching, or
crushing.

Recommendations:
1. Equip machines with guards and barriers around all moving parts to prevent
accidental contact.
2. Ensure all employees are trained on machine operation and safe handling procedures.
3. Implement lockout/tagout (LOTO) procedures during maintenance or when clearing
jams to prevent accidental startup.

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Hazard:
Entanglement Risks from Strands or Wires: The rotation of wires or strands during twisting can
entangle loose clothing, hair, or jewelry, leading to serious injuries.

Recommendations:
a) Require workers to secure long hair, avoid wearing loose clothing, and remove
jewelry when working near twisting and stranding machinery.
b) Clearly mark "no-touch zones" around twisting equipment to keep workers at a safe
distance during operation.
c) Provide safety training on the specific risks of entanglement and emphasize the
importance of following dress codes.

Hazard:
Strain and Ergonomic Injuries from Handling Heavy Reels:
The twisting and stranding process often requires handling heavy reels or spools, which can lead to
back injuries or musculoskeletal disorders from lifting or awkward postures.

Recommendations:
a) Use mechanical aids, such as hoists, forklifts, or conveyors, to lift and position heavy
reels, minimizing manual handling.
b) Design workstations to minimize bending, reaching, or awkward positions.
c) Rotate tasks and encourage regular breaks to reduce strain from repetitive motion.

Hazard:
Noise Exposure: Twisting and stranding machines generate high noise levels, which can lead to
hearing
loss over time if not properly managed.

Recommendations:
a) Conduct regular noise assessments and install sound-dampening materials around
high-noise equipment.
b) Provide hearing protection, such as earplugs or earmuffs, and require their use in
designated high-noise areas.
c) Limit exposure time for workers in high-noise areas and implement a rotation
schedule to reduce prolonged noise exposure.

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6. Extrusion:
Extrusion involves subjecting materials to plastic deformation by applying force and guiding material
flow through a die or orifice. During this stage, engineers pass the wire through an extruder, applying
a coat of plastic or alternative insulating material. [5]

FIGURE 9: CABLE EXTRUSION MACHINE

The extrusion process in cable manufacturing, where insulating and protective layers are applied to
conductors by forcing materials through a die, presents multiple hazards. These range from high-
temperature risks to exposure to chemical fumes and mechanical hazards. Below are common hazards
associated with extrusion in cable manufacturing and recommendations to improve safety.

Hazard:
Thermal Burns from High Temperatures: Extrusion machines operate at very high temperatures to
melt insulation materials (e.g., PVC, polyethylene), creating a risk of burns from contact with hot
surfaces or molten materials.

Recommendations:
1. Use insulating barriers or guards around high-temperature areas to prevent accidental
contact.
2. Require workers to wear heat-resistant gloves, aprons, and long sleeves to protect
against burns.
3. Implement regular maintenance checks and cooling-down procedures before any
repair or cleaning work on extrusion equipment.

Hazard:
Chemical Exposure from Fumes and Vapors: Heating certain plastics and insulation materials can
release hazardous fumes and vapors, including carbon and other toxic compounds, which can irritate
the respiratory system and skin.

Recommendations:
1. Install local exhaust ventilation (LEV) systems to capture fumes at the source and
maintain air quality.

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2. Provide personal protective equipment (PPE) such as respirators, especially in high-

fume areas.
3. Regularly monitor air quality and conduct health checks for workers exposed to these
materials to ensure that exposure remains within safe limits.

Hazard:
Fire and Explosion Risks from Flammable Materials: The use of certain insulation materials or
additives can create a fire risk, especially if flammable dust or vapors accumulate near heating
elements.

Recommendations:
1. Store flammable materials away from heat sources and provide proper ventilation to
reduce the concentration of combustible vapors.
2. Use explosion-proof equipment in areas with a high risk of flammable dust
accumulation.
3. Train workers in fire prevention and response procedures, and ensure that fire
extinguishers and suppression systems are readily accessible.

7. Cutting of cables:

Cables of different lengths are cut according to the required length.

FIGURE 10: CUTTING OF CABLES

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The cutting process in the cable industry, used to cut cables to specific lengths, presents various
hazards, primarily mechanical and ergonomic in nature. This process often involves sharp blades,
heavy equipment, and repetitive tasks, which can increase the risk of injuries. Here are common
hazards and safety recommendations for the cutting process in cable manufacturing:

Hazard:
Cuts and Bruces from Sharp Blades: Cutting machines use sharp blades that can cause severe cuts or
lacerations if workers accidentally come into contact with them.

Recommendations:
1. Install guards and safety shields around cutting blades to prevent accidental contact.
2. Provide workers with cut-resistant gloves, particularly for manual handling of cables
and blades.
3. Train workers on safe handling procedures and ensure that they keep hands and tools
away from the cutting zone while the machine is operating.

Hazard:
Entanglement Risks with Loose Clothing or Hair: Rotating parts in cutting machines can catch loose
clothing, jewelry, or hair, leading to entanglement and injury.

Recommendations:
1. Enforce a strict dress code, requiring workers to secure loose hair, avoid loose
clothing, and remove jewelry before working near cutting equipment.
2. Provide workers with appropriate PPE, such as hair nets or caps, to prevent
entanglement.
3. Place clear warning signs and reminders around cutting stations about entanglement
hazards.

Hazard:
Mechanical Injuries from Moving Parts: Cutting machines have moving parts, like rollers and feeding
mechanisms, which can create pinch points and crush hazards.

Recommendations:
1. Equip cutting machines with guards around moving parts to prevent accidental
contact.
2. Implement lockout/tagout (LOTO) procedures to disable machinery during
maintenance or when clearing jams.
3. Regularly inspect cutting machines for wear and ensure all safety guards are in place
and functioning.

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Figure 11: Rolling of wire(for REBA analysis)

REBA Assessment of this process:

Task Neck Trunk Leg Upper Lower Wrist Activity REBA Risk level
score score score arm arm score score score
score score
Manual +2 +1 +3 +1 +1 +2 +1 +4 Low
rolling of
wires
REBA recommendation of this process:
1. Use mechanical aids for heavy or difficult-to-roll wire reels.
2. Maintain a neutral posture and avoid twisting or bending.
3. Keep hands at waist level and close to the body.
4. Ensure a secure, slip-resistant grip on the reel surface.
5. Minimize rolling distances and use mechanical assists for long distances.
6. Avoid sudden movements and use smooth, controlled rolling motions.
7. Wear slip-resistant footwear and maintain a stable stance.
8. Take rest breaks or rotate tasks to reduce cumulative strain.
9. Use team rolling for large or heavy reels.
Implementing these REBA-based ergonomic recommendations helps reduce the physical strain and
musculoskeletal risks associated with manual wire rolling, making the task safer and more
manageable for workers.

Selection of industry:
We selected wire cable manufacturing industry named SC select cables. Wire cables are quite an
important product for any use in any industry or home for the transmission of current at high as well
as low voltage. The capacity of wire to carry voltage depends on the thickness of wire. That is the
reason wires with different range of thicknesses are being manufactured in Industry.

General view of work in industry:

The cable wires go through different processes like heating, annealing , extrusion and insulation
coating etc. There are physical, chemical and other hazards related to every process involved in
manufacturing of cable wires.

Industry culture and workers experience level:

The number of employees in SC select cables was 20-25. The workers were categorized in three
levels:

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Fresh workers:
These are the workers with little or no experience. They were just used as helpers of therir senior
workers in machine related tasks. Mostly they were used for loading and unloading of raw materials.

Intermediate experienced workers:

They are the workers with 5-10 years of experience. They are used in running and maintaining
machines. There safety awareness level is comparatively high. They can be trained on safety controls
easily.

Highly experienced workers :

They are the workers with 20-25 years of experience. They are aware about hazards and risks because
they are expert in their work related to machines. So, they can also be trained easily on safety
controls.

How to look for ergonomics hazards in industry:

According to HIRAAC, searching for potential dangers involves examining the workspace,
considering employees' feedback on possible hazards, evaluating the departmental procedure manual,
work instructions, standard operating procedures, past incident reports, material safety data sheets,
first aid/injury logs, and employees' health records. [6]

Framework of industry visit:

As a health and safety executive, it is important to visit industry very carefully to inspect and audit the
processes and observe the ergonomic hazards related to the industry. According to the statement of
our OEL, we have to evaluate according the human factor principles. Also we have to know about the
cultural and societal beliefs of workers to make our recommendations effective.

Hazards in industry:
The main purpose of our industry visit was to note the ergonomic hazards related to the workplace
and to suggest their effective safety management technique.

Ergonomic hazards:
Hazard Risk Control
Dim light Eye strain Proper lighting systems
Narrow space Collision of workers Proper layout designing
Long working hours Reduction in workers Planning of
productivity
Carrying heavy wire bundles MSD Using of small carriage wheel

Environmental hazards:
Hazard Risk Control
Contaminated water Damage to plants Water filters

Psychological hazard:

Hazard Risk Control

Price negotiation Mental stress Communication skills training

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Hazard categories excel sheet:

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Failure mood analysis of cable and manufacturing industry:

Failure Mode and Effects Analysis (FMEA) is a structured approach to identify potential failure
modes within a process or system, assess their impact, and prioritize actions to mitigate risks. Below
is an FMEA for the cable and wire manufacturing industry:

Step Potential Potential Potential Severity Occurrence Detection Risk Remedies

process/ failure mode effect of causes (s) (o) (d) priority
Function failure number
(RPN)
Raw Use of good Defective Supplier 9 5 4 180 Strict quality
material raw material wire error check
inspection
Extrusion Temperature Improper Sensor 8 6 5 240 Regular
process control insulation malfunction calibration
failure
Wire Uneven wire Increased Improper 8 4 6 192 Replace dies
drawing diameter resistance lubrication
Stranding Improper Reduced Machine 7 4 5 140 Alignment
process wire cable misalignmen check
alignment strength t
Quality Missing Defective Inadequate 9 3 6 162 Enhance
testing critical defect products testing testing
detection reaching protocols
customers

Packaging Improper Physical Manual 6 4 7 168 Train staff

coiling damage errors
during
transport

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Fault tree analysis of cable and manufacturing process:

Fault tree analysis creates a graphical representation to illustrate how various failures can lead to a
system-wide breakdown. Key features of FTA include: A top-down approach: FTA starts by
identifying a critical system failure and then explores possible causes or sub-causes that led to the
breakdown.

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Conclusion:
The evaluation of working posture and surrounding environment using an assessment tool in the cable
and wire manufacturing industry highlights critical insights into occupational health and safety:
1. Postural Ergonomics:
Workers in this industry are frequently exposed to awkward and repetitive postures, such as prolonged
standing, bending, or reaching. These conditions increase the risk of musculoskeletal disorders
(MSDs). Improving workstation design and providing ergonomic aids can mitigate these risks.
2. Environmental Conditions:
Factors such as noise levels, lighting, and air quality often fall short of optimal standards, affecting
both productivity and well-being. Interventions like better ventilation, appropriate lighting, and noise-
dampening measures are crucial for enhancing the working environment.
3. Use of Assessment Tools:
The application of ergonomic assessment tools (e.g., REBA, RULA, or NIOSH lifting equation)
provides quantifiable data on risk levels. These tools are instrumental in identifying high-risk tasks
and prioritizing corrective measures.
4. Training and Awareness:
A lack of training in proper lifting techniques and ergonomic practices is a common issue. Regular
workshops and awareness programs can empower workers to adopt safer practices.
5. Impact on Productivity and Safety:
Poor posture and an unsuitable environment contribute to fatigue, injuries, and reduced productivity.
Addressing these issues not only enhances worker health but also improves overall operational
efficiency.

Recommendations:
1. Redesign workstations to minimize repetitive strain and encourage natural postures.
2. Implement environmental controls, such as noise reduction technologies and better
illumination.
3. Regularly monitor and reassess workplace conditions using established ergonomic
tools.
4. Promote an organizational culture prioritizing health and safety.
5. By addressing these findings, the cable and wire manufacturing industry can foster a
safer, more efficient, and sustainable working environment.

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sReferences:

1. https://www.researchgate.net/publication/298464170_Importance_of_Human_Factors_in_Ind
ustrial_Engineering_and_Design
2. https://osha.europa.eu/en/themes/musculoskeletal-disorders/practical-tools-musculoskeletal-
disorders/rula-rapid-upper-limb-assessment-tool
3. https://neuronflo.com/blog/reba-assessment
4. https://www.cdc.gov/niosh/ergonomics/about/RNLE.html
5. https://www.primecabindia.com/what-is-the-manufacturing-process-of-cables-and-wires 11
6. https://www.ncbi.nlm.nih.gov/pmc/articles/PMC5844132/
7. Figure 1. https://absolutepcbassembly.com/top-7-wire-and-cable-manufacturers-in-the-world/
8. Figure 6, 8, 9 https://fajarcables.com.my/manufacturing-process

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