Human Factors in Design & Ergonomics

The issue: Different, disconnected methods were being used for implementing human factors within different areas, and there was no strategic guidance for engineering projects.

The approach: The Keil Centre reviewed the organisation’s strategic philosophies and the methods in use. We developed a strategy document to integrate the approach for managing human factors within existing project processes. Our experts prepared guidance and procedures for applying human factors. This included a suite of company technical standards.

The outcome: The strategy, underpinning procedures and supporting technical standards were used on an engineering project. This enabled testing and refinement prior to being rolled out for new projects. It revealed more comprehensive consideration and demonstration of human factors and at an earlier design stage.

The issue: Staff working on a specific bottling and packaging line within the factory were experiencing back and upper limb pain. Some staff had taken time off from work with musculoskeletal injuries. The product and packaging had recently been redesigned. ​

The approach: Our experts performed a task analysis to understand the tasks at different workstations on the production line. We conducted postural analyses and assessments to pinpoint the key issues. We then supported the redesign of the product and the production line layout. Based on our recommendation, the client also introduced job rotation, work-rest cycles and postural training.​

The outcome: The production line modifications showed a marked reduction in risk for workers. The product redesign enabled improvements for both the workers and customers. Further assessments were undertaken to reduce issues elsewhere in the factory.

The issue: The design life of an existing platform was being extended by bringing on new fields. The control system had also become obsolete and the control room had evolved without a systematic approach.

The approach: Our experts performed analyses to understand potential human errors, workload issues and how the control room needed to support the operation. We developed the design concepts for the control room, control consoles, and control system graphics. We used expert reviews to guide the design and ensure compliance with human factors standards. We then tested the design with end users to enable the final refinement of the design.​

The outcome: Our end user reviews provided valuable feedback to the design team. We achieved good compliance with standards. This improved confidence in the design, buy-in from operators and acceptance of the safety case.