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OCR for page 133
CHAPTER 4. CONCLUSIONS
4.! Cost-Benefit Analysis
.
Many factors need to be included to estimate the costs of the prototype workstation.
The proposed workstation contains instrument panels that move. Therefore, increased
maintenance will result due to the devices that provide the movement. Also, the wires
and cable going into the instrument panels will require sheathing to protect from
vandalism and large loops to prevent failure due to fatigue. Other cost issues are shown
In Table 4.~. The instrument pane] supports will have to be strong for sufficient
durability such that they can withstand the vibration levels found on a typical transit bus
route. During the development of the workstation design guidelines, attention has been
paid to these issues. Of course, each manufacturer will have their own particular method
for implementation.
The cost investment can be broken down into five parts: fabrication, assembly,
installation, initial inventory, and tooling. Table 4. ~ shows the material costs and labor
costs. Blank spaces indicate no increase in cost over the conventional.
The material
costs include initial inventory, while the labor costs include fabrication, assembly, and
installation. The prototype did not require any special tooling.
- 4.!
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Table 4. I: Material and Labor Costs (unit: $)
Group | Itern | Material cost | Labor cost
Misc. Material plywood for instrument panels - 2 sheets 1/2x2x2 birch 10.34
2 inch corner braces -2 4.44
wood screws - 4 boxes 3.52
l
14 AWG wire, 170 ft 10.00
electrical tape- 1 roll 0.47
glue- 1 tube 1.88
duct tape - 1 roll 2.66
wire connectors - 3 boxes 7.83
spray paint - 2 cans 5.68
Al. sheet, 14 g, 24x36 25.44
Talking Bus System* installation (100 unit cost): $5400*
RIP fabrication, box (2 furs) 70.00
(right instrument panel) fabrication lid (2 furs) 70.00
additional switch for door 0.75
18 wood screws see above
2 solenoids for door 35.02 ea.) 70.04
Rl P Mount Al stock, 1 x3x1 /4x6ft 34.54
4 coaster wheels 0.76 ea 3.04
11 nuts, bolts, washers, 3/8x4 grade 8 6.62
6 nuts, washers, bolts, 1/4x4 grade 8 2.60
Al angle, 2x2x1/4x2ft (3/16, aft) 23.94
1/4 inch knob 0.93
Al bar stock, 2x7x1 /2 (aft) 35.52
fabrication and assembly, including 30 holes drilled 16.90
install, drill 4 1/2 holes in floor 36.40
Brakes Pedal
tubing, connectors, etc.
installation
Accelerator 227.00
Cl P wood accounted for above
(center instrument panel) fabricate - 0.5 day 140.00
20 wood screws see above
= 2.33
Pedestal fabrication and material 633.94
4grade8 1/2x4 4.05
6grade8 1/4x2 0.87
handle with knob 10.22
all thread - 1/2x16, 2 It 1.39
install, drill 4 1/2 holes in floor 106.40
steering column - ZF (100 unit cost) 1379.00
steering wheel 170.00
LIP wood and Al sheet already accounted for above
(left instrument panel) 4 clamps 29.76
18 1/4x2 grade 8 bolts 2.62
fabrication time 1 day
installation plus 16 holes 145.60
sunrise sign system 1 sign 600.00
seat upgrade 600.00
hands-free communication mic and power 175.00
set up time, rigging, layout, etc. 2 days 560.00
mirrors left and right 464.73 35.00
Sum $3917.21 $1814.24
Grand Total (Material and Labor) $5731.45*
* Talking bus is an electronic system integration tool as well as stop enunciator and data collection device. If system
integration is not included then the ODA is about $1400, for a total cost of $613 1.
- 4.2
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Cost-benefit analysis is a quantitative methodology used to justify the expenditure
of funds in controlling a problem situation or, more simply, the dollars spent per negative
utility reduction (Brown, 1976). Cost can be defined as the dollar outlay for the
incorporation of a device, method, or procedure for a given period of exposure. In this
particular study, it was the retrofitting of a standard bus with an ergonomic bus operator's
workstation, i.e., the material and labor costs (perhaps, also, increased maintenance costs)
for acquiring and installing the necessary components such as an ergonomic seat, a three-
degree-of-freedom steering column, and so on. There is a negative utility or dollar cost
associated with every injury. This could include direct costs such as medical expenses
and Workers Compensation and indirect costs such as lost time, replacement operator
training, etc. The benefit is defined as the reduction in the negative utility or decreases in
injuries and medical costs. The effectiveness of the corrective measure is then evaluated
by the ratio of benefit to cost with larger numbers indicating better utility or
effectiveness.
For the evaluation of the ergonomic prototype the actual costs incurred and
expected benefits from similar efforts pursued at various transit systems were utilized.
Thus, the costs of the materials, parts and components purchased for the prototype, plus
labor costs (A $30.00/hr) are summarized in Table 4.1 and total $6131. This cost is very
similar to the average cost of $6,901 incurred by BC Transit (Vancouver, BC) in their
redesign of the operator's workstation. An important aspect is that BC Transit did not
incur any increased maintenance costs from their improved workstation. The benefits are
projected on injury rate data, direct medical and Workers Compensation costs and per
cent decrease of injuries expected due to ergonomic redesigns.
Injury data - CTTRANSIT (Connecticut Transit) accumulated a total of 32
injuries over a 6 month period for 515 employees. This amounts to a yearly injury rate
per 100 workers of:
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' ~= ~ 2.43 9 or an injury rate of 0. ~ 243 per worker.
515x 1,000
Direct costs - CTTRANSTT expended a total of $87,000 ($42,000 in direct
medical costs and $45,000 in Workers Compensation costs) for these 32 injuries for an
average cost of $2,718. Data from BC Transit indicated average direct costs of $5,962.
However, these data were primarily back injuries (which tend to more expensive that
other types of injuries), as BC Transit had frequent problems with the seats bottoming
out. Both values will be utilized so as to give a range of expected benefit/cost ratios.
Injury reduction - The projected decrease in injuries due to the redesigned
ergonomic operator's workstation prototype is based on data from a similar venture at the
BC Transit system. They were experiencing a considerable number of back injuries due
to seats bottoming out and implemented a Recaro seat with additional workstation
modifications. In the year following the implementation of the modifications they found a
78°/O decrease in the injury rate (from 1.92 to .43 per 1,000,000 km) and an 88% decrease
in the severity rate (from 29.42 to 2.72 days lot per 1,000,000 km). These values are very
similar to those experienced by one of the investigators (A. FreivaIds) in industry. Over a
three year period after implementation of an ergonomic program (workstation redesign,
tool changes, training) in an automobile carpet manufacturing facility, the number of
injuries decreased by 74%. Therefore, a projected injury reduction rate of 80% for this
prototype is not unusual.
The benefit/cost ratio is then defined as the dollar cost reductions per workstation
implemented per cost of a workstation, or:
t°rs~shifts~b )< {injury_ rate_ per_ wor ker } x {average_ injury_ cos ~ } x {°/0_ reduction }
workstation cos
- 4.4
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Typically one bus would be used for approximately 14 shifts a week. With each operator
working 5 shifts a week, we would expect 14/5=2.8 operators per buss The injury rate per
worker from CTTRANSIT is 0.1243. Average injury cost ranges from $2,718 to $5,962
and an 80% injury reduction is expected. This results in a benefit/cost ratio ranging from:
2.8 x 0.1243 x $2,71 ~ x 0.~/$6, ~ 3 ~ = 0.123
2.8 x 0.1243 x $5,962 x 0.8/$6,131 = 0.27
These are calculated on a yearly basis, therefore taking the inverse would result in the
number of years it would take to pay off the cost of a workstation with decreases! medical
costs. The payoff time would range from I/.27=3.69 to I/.123=~.] years. These values
are probably low and payoff time could be expected to be shorter because of several
variables that are most likely true but difficult to account for in the direct calculations.
Only direct costs are utilized. There are many indirect costs such as lost time, need for
replacement operators, training costs for replacement operators, etc. that impact a transit
authority. Also. medical and hospitalization costs have been skyrocketing over the past
few years and will likely to continue to do so in the future. Therefore, the above costs
may be considerably on the low side and payoff time may be considerably faster.
- 4.5
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4.2 Final Design Specifications and Guidelines
The workstation should contain several features that are essential to accommodate
the population extremes. Figure 4. ~ -4.4 show photos of the prototype workstation. Also,
the workstation concept for the guidelines can be found in Chapter 2.~. The necessary
components are:
a 457 mm (! ~ inch) steering wheel
hanging pedals
tilt-telescoping steering column (minimum requirement), (tilt-telescoping-tilt ideal)
· low profile farebox
· pin joint suspension operator seat
· seat with air actuated lumbar and back side bolster support features preferred
turn signal platform located on the floor angled at 30 degrees housing the turn signals,
and high beam switch
· adjustable (height and fore-aft adjust) instrument panels that are divided into left,
center and right.
Operator Digital Assistant (ODA) to act as the central interface to the bus electronics
system
Remotely activated mirrors
Annunciator system which allows push button
activation of pre-recorded
announcement messages (similar to the Talking Bus system) is preferred (A "hands
free" communication system would be ideal).
- 4.6
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- - -
Figure 4. i: Left and Right Instrument Panels
_ ~
Am. ,,,~6,-~
~`:- ~ __ ~
:: Hi
... ., ., v. ~ .~, ~
OO ]
O:H
~.~
_
A_
r- it:
~ If'
Hi" 'A-__ ~c;<
~.:~
. .
Figure 4.2: Center Instrument Panel
- 4.7
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~ ~ _
Hi. ~ <' ~ ~ {
t: ~:' ~::: ~ .' : ~ - I:
ail: ::: ~' ~ ~ ~' ::
Hi-: : :: . ~
,-., ? ~4 _ _
Figure 4.3: Hanging Pedals
Figure 4.4: Prototype Workstation
- 4.8
r.~.
:-,
.._
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The following figures and tables detail the necessary locations and adjustment
ranges for the proposed workstation design. Figure 4.5 - 4.7 below are drawings of the
The reference points are listed in terms of 5th percentile
female, 50th percentile, and 95th percentile male, and are defined in Table 4.3. Also, Table
locations listed in Table 4.2.
4.4 details all of the design specifications necessary for the workstation.
.v
Table 4.2: Guidelines - Component Locations (units: cm)
Reference SAE 5% Female SAE 50% SAE 95% I\ dale
Point x I y I z x l Y T z x I Y
BURP9.3 1 0.0 1 29.6 0~0 1 00 T 36.7 -9.3 T °~°
SWRP 48.8 0.0 63.2 44.3 0.0 66.3 39.8 0.0
1LIPRP 43.1 33.0 47.6 38.1 33.0 49.6 33.2 33.0
RIPRP 51.9 -39.0 65.0 45.2 -37.0 67.2 38.6 -39.0
BPPRP ~ 86.6 8.9 11.6 86.6 8.9 ~ 1.6 86.6 8.9
APPRP 86.4 -21.8 9.0 86.4 -21.8 9.0 86.4 -21.8
z
43.9
69.5
.
51.6
69.5
.6
9.0
- 4.9
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Table 4.3: Reference Point Definitions
Ref. Point Definition
APPRP Accelerator Pedal Plate Reference Point. Located on the center of the top
surface of the accelerator pedal plate. if the pedal plate pivots about the
pedal arm, then the reference point is to be located at the pivot location
projected normal onto the pedal plate surface.
BPPRP Brake Pedal Plate Reference Point. Located on the center of the top surface
of the brake pedal plate. If the pedal plate pivots about the pedal arm, then
the reference point is to be located at the pivot location projected normal
onto the pedal plate surface.
LIPRP Left instrument Pane! Reference Point. Located in the center of the top
surface of the left instrument panel.
RIPRP Right Instrument Panel Reference Point. Located in the center of the top
surface of the right instrument panel.
SRP Seating Reference Point. The point on the sagittal plane located by two
intersecting planes - the compressed seat pan and seat back. If SgRP
| (Seating Rei erence Point, which is the H-point (hip pivot point) of the 95th
percentile person of the US population as defined by SAE J1 100) is known
from seat manufacturer data, can use the following equations (SAE J1 100,
SAE J826):
horizontal distance of SgRP from SRP = HL12 - HL1 1 x cos(SB1 1)
vertical distance of SgRP from SRP = HL1 1 + HL12 x sin(SP9)
where: SB 11 is the seat back neutral vertical angle
SP9 is the seat pan neutral horizontal angle
HE1 ~ is the vertical length from hip pivot to SRP (9.8 cm)
HL12 is the horizontal length from hip pivot to SRP
(13.4 cm)
SWRP Steering Wheel Reference Point. Located in the center of the plane of the
steering wheel
WO Workstation Origin. Located on the workstation platform directly
underneath the NSRP.
- 4.10
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Table 4.4: Complete Guideline Specifications for an Ergonomic Bus Operator's Workstation
Design Variables Code Design Value
seat horizontal distance of NDEP from NSRP SH9 5.9 cm
vertical distance of NDEP from NSRP SH10 75.8 cm
seat back neutral vertical angle SB11 10 deg.
seat back angle adjustment range SB12 10 deg.
seat pan neutral horizontal angle SP9 5 deg.
seat pan angle adjustment range SP10 0 deg.
seat fore/aft adjustment range SP1 1/ 1 8.5 cm for total of fore- and
SP12 aft- adjustments
Went range SP13/ 14.3 cm for total of upward
SP14 and downward adjustments
vertical distance of NSRP from WO SP15 36.7 cm
steering wheel diameter TW1 45.7 cm
wheel wheel plane neutral horizontal angle 1W5 40 deg.
wheel telescope adjustment range iW7 11.0 cm
wheel plane horizontal angle adjustment range 1W8 20 deg.
horizontal distance of NSWRP from NSRP TW10 44.3 cm
vertical distance of ~Y TW11 29.6 cm
Brake ~ _ PB1 8.0 cm
Pedal brake pedal plate width PB2 10.0 cm
brake pedal plate shape PB4 curved
brake pedal plate lateral angle PB5 0 deg.
brake pedal plate horizontal angle PB6 40 deg.
brake pedal plate pivot angle range PB7 0 deg.
lateral distance of BPRP from NSRP PB8 8.9 cm
horizontal distance of BPRP from NSRP PB9 86.6 cm
vertical distance of BPRP from WO PB10 1 1.6 cm
brake pedal actuation angle PB20 30 deg.
brake pedal actuation force PB21 66.8 ~ 155.8 N
brake pedal recovery force PB22
Accelerator accelerator pedal plate length PA1
Pedal accelerator pedal plate width PA2 5.6 cm
accelerator pedal plate shape PA4 flat
accelerator pedal plate lateral angle PA5 12 deg.
accelerator pedal plate horizontal angle PA6 30 deg.
accelerator pedal plate pivot angle range PA7 10 deg.
lateral distance of APRP from NSRP PA8 21.8 cm
horizontal distance of APRP from NSRP PA9 86.4 cm
vertical distance of APRP from WO PA10 9.0 cm
accelerator pedal actuation angle PA20 20 deg.
accelerator pedal actuation force PA21 31.2 ~ 40 N
accelerator pedal recove~ force PA22 .~ i
Left left instrument panel horizontal angle IL5 5 deg.
Instrument left instrument panel horizontal adjustment range IL6 9.9 cm
Panel left instrument panel vertical adjustment range IL7 4.0 cm
lateral distance of NLIRP from NSRP IL8 33.0 cm
horizontal distance of NLIRP from NSRP IL9 38.1 cm
vertical distance of NLIRP from NSRP IL10 12.9 cm
Right right instrument panel horizontal angle IR5 30 deg.
Instrument ~ _ _ IR6 13.3 cm
Panel right instrument panel vertical adjustment range IR7 4.5 cm
lateral distance of NRIRP from NSRP IR8 37.0 cm
horizontal distance of NRIRP from NSRP IR9 45.2 cm
vertical distance of NRIRP from NSRP IR10 30.5 cm
- 4. ~ ~
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4.5 Conclusion
From the above results the key conclusions are: 1) The bus operator workstation
can feasibly be redesigned using ergonomic principles so as to accommodate individuals
ranging from the 5th percentile female to the 95th percentile male; 2) The specific
prototype designed and constructed by this project was judged superior to the existing
workstation by a representative jury of actual bus operators; 3) It is estimated that the
additional cost to incorporate the final design guidelines of this research in new buses
will be more than offset by savings in terms of reduced operator injuries and worker's
compensation claims.
The final result of the above work is a guideline for the design of a bus operator
workstation that can accommodate the population extremes. This report develops the
guideline through rigorous analysis, synthesis and testing. The guideline is presented in
two formats; a simple to use version that is essentially a set of engineering drawings
which can be incorporated directly into a bus specification and a set of functional
relationships which can be used a guide to design workstations with specific features or
requirements.
Future enhancements can be designed into the workstation as costs permit. Some
of these enhancements may include, a memory such that operators can type in a number
into the ODA and the components automatically move to preset locations, active
vibration control in the seat to accommodate the wide variety of road roughness as well
as population, a more adjustable seat pan such that all population ranges are
accommodated, and a steering wheel tilt. The prototype constructed in this work did not
include a steering wheel tilt because a suitable commercial product could not be located.
It was elected for safety reasons not to use an "in-house" construction. In other works
that included a steering wheel tilt, the tilt was a physical distance from the hub of the
wheel. However, it is felt that the steering wheel tilt would provide improved visibility as
well as comfort.
- 4.24
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Future research is required to develop a further understanding of issues involved
and to develop cost effective solutions. Each aspect of this project could be expanded to
become research projects unto themselves. However, the significant recommendations
for future research include the following:
1) The development of an anthropometric data set focused towards the industry.
This would allow refinement of the above guidelines.
2) A critical in-depth study of seating comfort including vibrations and long term
static comfort. This work should also identify the influence of the operator manipulating
the controls on the vibration levels. in addition, the vibration levels found in a typical
transit bus should be characterized.
3) This project dealt with the operator's immediate work areas. Future studies
should take a comprehensive approach to the entire bus and its layout. For example, can
the farebox be reconfigured to provide more visibility and room ? Is the door in the
optimal location ? Is the vehicle dynamic properties such as its pitch natural frequency
optimal ?
4) Education programs should be developed to educate operators about
ergonomics, safe postures, and proper use of equipment like seats that have a variety of
adjustments.
- 4.25
OCR for page 158
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Representative terms from entire chapter:
steering wheel