Development of Ergonomics Furniture

DEVELOPMENT OF ERGONOMICS FURNITURE FOR PRIMARY SCHOOL IN MALAYSIA 1

NURUL ASYIQIN MOHD ALI, 2SHAMSUL BAHRI MD TAMRIN, 3MOHD SHARIZAL DOLLAH, 4 MOHD RAFEE BAHARUDIN, 5MUHAMAD AZHAR MOHD NOR, 6 VELU PERUMAL AND 7NORHISHAM SEYAJAH 1,2,3,4,5

University Putra Malaysia, Malaysia, 6LimKokWing University of Creative Technology, Malaysia. 7 University Kuala Lumpur, Malaysia.

ABSTRACT

1. INTRODUCTION

The implementation of ergonomics improvement is a new concept in Malaysian society. This study is mainly focused on improving primary school furniture based on user centered design concept, hazard identification, risk assessment and control (HIRARC), anthropometry and cognitive ergonomics. The result from HIRARC assessment shows that ergonomics risk factors found to be significantly associated in contributing to musculoskeletal disorders (MSD) among school children particularly when using the existing furniture. From the risks identified, development of ergonomics furniture was done by identifying the preference of the student using a simplified questionaire. Anthropometric data was collected to determine the specification of the furniture based on the anthropometry of level 1 (standard 1 to standard 3 children) and level 2 (standard 4 to standard 6 children). Using all the important information, several 2D sketches and 3D mock-up model were produced and only one final design was selected based on the need of the students. The specification of the furniture was finally intergrated with anthropometric data for final design specification prior to final fabrication of prototype.

Ergonomics is a science of adapting environment to human capacity. In Malaysia recently, a rapid improvement has been done to improve the wellness and health of either workers or people that have direct contact with interface. In Occupational Safety and Health Act 1994, under section 4 – 5 (Part 1-2) directly refers to the importance of ergonomics, “To promote an occupational environment for persons at work which is adapted to their physiological and psychological needs”.

Keywords: ergonomics furniture, user centered design, cognitive ergonomics, design process and primary school

Ergonomics improvement tends to increase the safety and health in a workplace and in addition improve output such as productivity and outcome of a working/ environment setting. Therefore in Malaysia, many of the ergonomics improvement tends to focus on industrial and occupational setting but lack of ergonomics assessment for school environment. Although few researches had been done in Malaysia that revealed poor ergonomics environment in Malaysian schools, no action was taken by the government and Ministry of Education (MOE) (Tamrin et al., 2004). In addition, currently no record of school (infrastructures such as building, school layout, class room and the school children) had been designed or promoted on application of ergonomics. Therefore, the research group had proposed 3 main parameters for ergonomics improvement in Malaysian schools viz; 1) school building and layout – minor/ low cost adjustment of school building and class room to fit 95% of schoolchildren anthropometry and school safety such as traffic flow in and out of school, 2) desk and chair (classroom furniture) – to fitting 95% of

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UNIVERSITI PUTRA MALAYSIA Fakulti Rekabentuk dan Senibina

schoolchildren based on their anthropometry and finally 3) bag load – to determine the prevalence of musculoskeletal disorders (MSD) and the risk factors among school children due to excessive weight carried and to design a solution in reducing bag load. By implementing these 3 strategies, the researcher will be able to 1) increase safety and health within and adjacent areas of the school and 2) increase productivity of schoolchildren, teachers and staff. However, this paper will focused on the development of ergonomics table and chair for primary schools in Malaysia.

2. LITERATURE REVIEW Ergonomics is the theoretical and fundamental understanding of human behavior and performance in purposeful interacting socio-technical systems and the application of that understanding to design of interactions in the context of real setting (Wilson, 2000). In simple words, ergonomics is a science of fitting environment, task or product with human capabilities. In order to do so, the design of furniture, daily product or workplace setting should adapt the ergonomics approach in daily life. The implementation of ergonomics concept includes components such as cognitive ergonomics, design based on target population anthropometrics features and user centered design (UCD). Cognitive ergonomics is a concept to fit between human cognitive abilities and limitation with the product, task and environment (Chengalur et al., 2004). UCD is a design process in which end-users influence how the design takes shape (Abras et al., 2004). The main focused of this concept is incorporating the user, task and environment into the design process. Anthropometry is a science of measuring human bodies which includes measurement of body size, shape, strength and working capacity (Pheasant and Haslegrave, 2006). The combination of all the concepts will produce ergonomics product which can increase comfort, safety, health and productivity in both working and nonworking environment. Risk assessment is a process of evaluation of the risk to safety and health arising from hazards (DOSH, 2008). The assessment includes hazard identification, risk assessment and risk control (HIRARC). The main purpose of HIRARC is to identify the factors that may cause harm to employees and


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others (the hazards), to consider what the chances are of that harm actually befalling anyone in the circumstances of a particular case and the possible severity that could come from it (the risks) and to plan, introduce and monitor preventive measures to ensure that the risks are adequately controlled at all times (DOSH, 2008).

3. MATERIAL AND METHOD A cross-sectional study was done involving 843 primary schoolchildren aged 8 (representing level 1) and 11 years old (representing level 2) in 4 regions in Peninsular Malaysia. Random sampling was used to select the states, districts and schools. Four states were randomly selected from the list of thirteen states viz Selangor (central region), Pahang (eastern region), Perak (northern region) and Johor (southern region). Ten primary schools participated in this study. The sampling frame of the schools was obtained from the Malaysian Ministry of Education (MOE). Due to difficulties to separate the children from the class, therefore the study randomly selects among the list of class from level 1 and level 2 in every school. The class and respondent name list were obtained from the latest database of each school. 3.1 Questionnaire A set of interviewed questionnaire was distributed to the respondents during school hours. The questionnaire session was conducted in a group and prior to the session, each group was briefed on the correct procedure of completing the questionnaire. The respondents answered all the questions under the supervision and guidance of research assistants. The questionnaire includes socio-demographic and background information such as ethnicity, gender, age, type of transportation, sports activities and leisure activities such as playing video games and using personal computer. In addition it was used to determine prevalence of musculoskeletal disorders (MSD) and risk factors including additional data to be used as part of design development. The MSD questions include 9 body parts and also the overall MSD (any MSD symptoms at any body parts) using translated modified NORDIC questionnaire (Kuorinka et al., 1987). The body parts include neck, shoulder, elbow, arm, upper back, lower back, hip and thigh, knee, leg and overall MSD. Questions were given to students in level 1 and level 2 groups to ascertain the level of

severity between lifetime prevalence and within 7 days for acute MSD. Other than that, the children were also asked regarding their perception whether the existing furniture is the factor of reported pain complained. The children were asked to determine the design material based on the respondent preferences as an application of user centred design approached. In determining the type of colour preferences, a simple colour group was given such as 1) light coloured group and 2) dark coloured group. Four types of light colours used were a) sea blue b) yellow c) red and d) bright green. The dark colours were represented by a) dark blue b) dark green c) violet and d) dark brown. In addition to color preference, the type of material prefered was also proposed to the schoolchildren. The type of materials used is an essential part in determining the most suitable comfortable furniture developed for the student. This concept is known as participatory ergonomics and user centered design approch in which solution for improvement includes the preference by the user (Marras and Karwowski, 2006). The type of materials used is an essential part in determining the most suitable comfort furniture developed for the children. The types of material proposed include metal, wood, plastics and aluminium while material combinations include metal – wood, metal – plastics, wood – plastics, aluminium – wood, aluminium – plastic. In addition, the questionnaire also includes the previous design of classroom furnitures, shapes, texture and the prefered classroom setting.

and estimating risks from each hazard involved where the RA involves calculating or estimating the likelihood of occurrence and severity of each hazard identified, and 4) determining each of the risk identified and to decide whether the outcome is acceptable or necessary control measures need to be applied. The process of HIRARC was based on the guidelines by the Malaysian Department of Safety and Health (DOSH) (DOSH, 2008). 3.3 Anthropometric Measurements The respondents’ body weight and their school bag weights were measured using the same digital electronic weighing scale. Body Mass Index (BMI) was calculated as body weight in kilograms divided by the height in meters squared. Measurement was taken thrice for each respondent and his or her school bag in order to determine the average weight. Anthropometric measurements were used using the Martyn type anthropometer (Figure 1) and each of the respondents was requested to sit on a customized made chair as shown in Figure 2. The anthropometrics measurement was based on protocol by Pheasant & Haslegrave (2006). The customized chair was designed in order to ensure that the measurement seat is not padded with any soft materials and also to ensure that the student can seat at right angle and the seat height can be adjusted based on their popliteal height.

3.2 Risk Assessment Severity of the risk of MSD among the respondents was determined using the odds ratio (OR) and risk assessment (RA) method. The OR was determined by using binary logistic regression adjusting for body mass index (BMI), sport activities and history of previous accident. The severity of the risk was determined using the Hazard Identification Risk Assessment and Risk Control (HIRARC) method with four main processes in sequence. The sequence includes the following: 1) classification of school children activities, 2) identify hazards through school’s daily activities that could pose significant risks to the health and safety of students, 3) conduct RA by analyzing

Figure 1: Martyn type anthropometer

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using simple wood materials. Finally, the full scale school furniture prototype was developed using real material preferred by school children. Figure 3 shows the summary of furniture development process.

Figure 2: Customized anthropometry chair 3.4. Furniture Design and Measurement The school furniture development process begins with the prioritization and identification of ergonomics problem in selected classroom. The furniture design and development process was based on methods and specifications suggested by Chuankai & Yinghui (2004) and Hassan & Ahmad Rizal (2008). Based on the problem identified, the idea of new design was created by determining the concept and specification of the new furniture. The design process began with proposed 5 idea sketches and only 1 sketch was selected. In the next stage, the 2D layout of selected design idea was drawn and technically drafted by hand and using Solid Works software. The full scale 2D drawing integrated with proposed furniture dimension was done to help in considering aspects of form, proportion and consideration of accurate measurements and materials in the development of design. After that, the 3D surfacing and details were done using Solid Work software. With the 2D and 3D drawing established, a real mock-up size model was developed


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Figure 3: Furniture Design and Development Process

3.5 Quality Control and Data Analysis

Table 1: Respondents Background Information

Each of the standard operating procedures (SOP) was followed to maintain quality control. The questions used in this study showed good reliability (Cronbach alpha of 0.918). This study uses univariate analysis in determining the prevalence of MSD and in determining the measurement of anthropometry while the risk factors were determined using HIRARC and statistical analysis of binary logistic regression. The statistical test was analysed using statistical package of social sciences (SPSS) version 13 software. The ethics of this study had been approved by Faculty of Medicine and Health Sciences, Universiti Putra Malaysia Ethics Committee [Ref: UPM/FPSK/ PADS/T7-MJKEtikaPer/F01 (LECT_Oct11)].

4.

RESULT

4.1 Background Information From the total respondents, 48% were males, 52% were females with the mean body weight of 29.48 ± 10.12 kg, and mean height was 128.25 ± 10.59 cm. The average BMI was 17.2 kg/m2. Most of study respondents were from Malay ethnicity (92%) and the average parents’ income was RM 1,612 ± 1397. Over 93% of the school children played sports either during school or after school hours. The most popular sport was football (30%), followed by cycling (23%), badminton (13%), netball (12%) and other sport activities such as swimming and martial arts (9%). In addition, most of the children reported having indoor activities (94%) such as playing computer game and watching television before or after school hours. A high majority of them (64%) reported that they travelled to school by vehicle such as car, motorcycle and bus, only 10% of them cycled to and back from school and a small fraction of the school children walked the whole way (to and fro from school). Table 4.2 summarizes the overall demographic information.



4.2 Prevalence of MSD

4.3 Risk Assessment

The result shows that the overall prevalence of MSD (life time) is very high and above acceptable level (66.5% for level 1 and 73% for level 2). The study revealed that for life time prevalence of MSD, 33% of the children reported that they had knee and leg pain (KLP) once in a life time followed by shoulder pain (SP) 32%, neck pain (NP) 31%, arm pain (AP) 20%, hip and thigh pain (HTP) 17%, upper back pain (UBP) 16%, elbow pain (EP) 14% and 11% of them reported lower back pain (LBP) at least once in their lifetime. The study also shows that KLP (32%) was the highest complaint among level 1 children, but level 2 children showed that NP was the highest (35%) compared to the other body parts. Musculoskeletal complaints of within the seven days of interviewing also showed slightly lower prevalence of MSD and the same trend was observed. The result showed that the highest prevalence was KLP (16%), followed by NP and SP (13%), AP (9%), HTP (8%), EP (7%), while both UBP and LBP reported 6% of the total samples for at least a day or more within 7 days of MSD complaints preceding completion of the questionnaire. The study also showed the highest prevalence of KLP among level 1 (17%) and 2 (16%) compared to the other body parts. Details are shown in Table 2.

From the assessment, the study revealed that 4 ergonomics parameters were found to be hazardous to pupil namely; 1) un-ergonomically designed furniture 2) awkward posture 3) prolong sitting 4) excessive loading. There are 7 locations involving pupil main activities during school hour which are 1) classroom, 2) sciences laboratory, 3) living skills workshop, 4) music room, 5) audio visual laboratory, 6) canteen and 7) sanitary facilities.

Table 2: Prevalence Of MSD For Malaysian Primary School Children

Among the children working activities, classroom learning indicates the highest risk level of 15 (high risk) compared to others. Through observation, all levels of school children ranging from standard 1 up to standard 6 were found using the same design of school furniture regardless of their body anthropometric. The same design of chairs and tables was found in all classrooms, science laboratories and workshops. Table 3 shows the summary of ergonomics hazard identified in classroom environment. The high risk indicated an immediate response that requires action taken to control the hazard as in the hierarchy of control. As required in HIRARC by Department of Occupational Safety and Health (DOSH), any corrective or intervention program must be documented and further ergonomics assessment follow up is well encouraged. 4.4 Risk Factors In determining the risk factors of MSD among the primary school children in Malaysia, Binary Logistic regression analysis (BLR) was used. Using each body part and determinating risk, controlling of sport activities, history of previous accident and body mass index, the risk factors indicated that furniture and school bag showed an increase in odd ratio/risk from 1.67 (leg) to 5.25 (shoulder). This would indicate that the risk of developing leg pain was 1.67 times higher for those who carried heavy school bag (>10% body weight) compared to those who carried less and the risk of developing shoulder pain was 5.3 times higher among those who carried heavy school bag compared to those who carried less. The result also indicated that the risk of developing upper back pain was 4.6 times higher among those who used un-suitable furniture (Table 4).


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Table 3: Risk Level Assessed Among Primary School Children

Table 4: Association between Risk Factors and Complain Of MSD

Table 5 : Type Of Materials Prefered By The School Children

4.5 Design Material based on Student Preference The result shows that majority of the schoolchildren (76%) prefered light colors to be used as furniture colors. Therefore, the developed furniture will be chosen from the 4 colors proposed to the pupils. The result revealed that majority of the students prefered wood component as the major material used and the combination of metal and wood to be the most prefered combination of materials as shown in Table 5.

4.6 Furniture Dimension For seat anthropometric needs, 6 measurements were used namely; 1) sitting height, 2) sitting shoulder height 3) popliteal height 4) buttock to popliteal length 5) sitting elbow height and 6) hip breadth. As design principle, height measurement used 5th percentile of the school population while seat length used 95th percentile as recommended by Pheasant & Haslegrave (2006). Corrective measure for shoes was also included (40mm). In addition for table height, 2 parameters were used namely 1) sitting elbow height and 2) sitting height with the design principle of 5th percentile. For the whole Peninsular Malaysia, a total of 640 anthropometric data was collected. Table 6 shows the furniture parameters and anthropometrics dimension used.



Table 6: Furniture Dimension

4.7 Furniture Development The design concept was based on the ergonomics problem of the current existing furniture. Therefore, the furniture must be designed to reduce static posture, awkward posture (bending, bending and twisting, bending of the neck and shoulder), able to reduce the bag load carried by the student and equally match with the anthropometry of the schoolchildren. A total of 5 initial sketches had been proposed. From the sketches, only a single design was chosen by the overall team after a series of discussion. This is to ensure that the design would maximize the safety and health theme and their comfort ability. The next step is to convert the sketches into 2D and 3D designs and also to incorporate the anthropometric measurement for both level 1 and level 2. In the 2D and 3D designs, all the relevant measurements were used as part of design and development. With the 2D and 3D model established, a real mock-up size model was developed using simple wood materials. The mock-up model was made several times with adjustment and modification until the final design suit the entire research group especially in fitting the size and also to determine a better method of improving safety issues such as accident that can cause bodily injuries (Figure 5).


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Figure 4: Selected sketches for ergonomic school furniture

Development of prototyping was one of the major parts of the research, in which the first prototype (PR Ver. 1) was based on the final data on the mockup model. The final prototype was also assessed by the team members in order to determine any major defect and flaw of the final mock-up measurements. The development of one set of PR Ver. 1 was done within the approximately time frame of 2 weeks. The basic prototype used most of the given information in order to follow the preference of the school children. Figure 6 shows the PR Ver. 1 of school furniture.

5. DISCUSSION Recently, many studies had been done in identifying the MSD complaints and risk factors of MSD problem among children (Haselgrove et al., 2008, Murphy et al., 2007; El-Metwally et al., 2007; Navuluri et al., 2006; Grimmer et al., 2006). The example of ergonomics risk factors that exist among children from previous studies are classroom posture, school bag load, school furniture and anthropometrics parameter (Smith & Leggat, 2007; Murphy et al., 2004; Trevelyan & Legg, 2006 and Philippa and Stephen, 2004). In an attempt to understand the severity of MSD among Malaysian primary schoolchildren, a preliminary study was done to determine the prevalance of MSD and to prioritize the risk using regression analysis and Hazard Identification, Risk Assessment and Control (HIRARC) as tools in determining the severity.

Figure 6: School furniture prototype (PR Ver. 1)

The overall findings of this study in identifying the risk factors and risk assessment of ergonomics problem in school environment showed that school children were highly exposed to early stage of MSD due to improper design and dimension of classroom furniture especially chair and table used by the children. The same findings were found in study by Gouvali et al. (2006) and Parcells et al. (1999). Un-ergonomics furniture may lead to awkward posture during school session as reported by Troussier et al. (1999).

Figure 5: Model mocking using anthropometrics furniture dimension



While study done by Kratenove et al., (2007) found a significant occurrence of poor posture between children aged 7 years old and 11 years old. Another study by Chung and Wong (2007) also revealed poor ergonomics application in school setting. It highlights the ergonomics problems found in Hong Kong primary school classroom. In theory, the application of ergonomics concept will increase safety and health in daily life (Mokdad and Al-Ansari, 2009; Chengalur et al., 2004; Wilson, 2000). Therefore, based on result of prevalence of MSD, HIRARC and risk factors, the findings conclude that the current furniture used have many flaws and weaknesses that may contribute to ergonomics problems such as MSD and CTD cases. Hence, ergonomics and design solution is needed as a corrective measure in reducing the health effect of Malaysian primary schoolchildren. Molenbroek et al. (2003) also found that school furniture size for European children does not cover the entire target population. Various types of furniture were used by all the schools. From our observation, the usage of school furniture was non-standardized where basically two main size specifications were used (Level 1 and level 2). From the measurement of the existing furniture, the result concluded that the current seat did not match with both Level 1 and Level 2 anthropometric measurements. In the development of ergonomics furniture, the industrial design process was integrated with ergonomics concept in order to produce new ergonomics furniture for primary school in Malaysia. The industrial design process was based on ergonomics problem and safety identified in the classroom and it comprised of proposing design concept followed by developing mock-up model and fabricating of prototype Version 1. Development of prototyping was one of the major parts of the research, in which the first prototype (PR Ver. 1) was based on the final data of the mockup model. The final prototype was also assessed by the team members in order to assess any major defects and flaws of the final mock-up measurements. The development of one set of PR Ver. 1 was done within (the time frame of approximately) 2 weeks. The basic prototype used most of the information asked in order to follow the preference of the school children. According to Hassan & Ahmad Rizal (2008), the important aspects in industrial design include quality of the product, aesthetic value, colors, ergonomics,


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technology, safety, standard and regulation. The criteria of the proposed furniture include design based on user-centered and cognitive ergonomics where such research had been done before the design process started to determine the risk factors of MSD problem, elimination of weaknesses of existing furniture, and design based on the children preferences. In order to increase the comfort and reduce the ergonomics problem, the furniture was designed based on Malaysian school children anthropometrics dimension and the table top was designed to be adjusted into 4 levels which are, flat (normal table), 5o increment, 10o increment and 15o increment. The criteria were set up to fit 95% of primary school children and to reduce the flexion of neck, upper back and shoulder during writing and reading. Other than that, the proposed adjustable table top for school table and arm rest for school chair is a new ergonomics improvement introduced by this study. The evaluation studies on the effectiveness of PR Ver. 1 included posture analysis and school bag weight measurement. The manufacturer was given a duration of 1 month to fabricate and manufactured a quantity of 80 sets of ergonomics furniture consisting of 40 sets of PR Ver. 1 for Level 1 (primary 2) and another 40 sets for Level 2 (primary 5). To ensure that the furniture could easily be transported, it was built as single parts. The ergonomics furniture was then reconstructed again in the field. The evaluation study of PR Ver. 1 indicated that the total rapid upper limb assessment (RULA) score was reduced from more than 5 to less than 3. This indicated that the new furniture was able to reduce the risk from un-ergonomic furniture.

6. CONCLUSION In conclusion, this study proposes new design and concept of school furniture in primary school. The findings in this study can benefit the Ministry of Education in improving the standard and to promote awareness in terms of safety and health and ergonomics of Malaysia schools. In addition, the findings in this study will be used to formulate the most cost effective ergonomics improvement program for Malaysian schools in reducing the risk and preventing MSD among children. Finally, this research is very important since it will translate research finding into profit from commercialization and benefit not only UPM but also to the National wealth in general.

ACKNOWLEDGEMENT This study was supported by Universiti Putra Malaysia under the Research University Grant Scheme (RUGS) (04/01/07/0128RU). The author would like to extend gratitude to Malaysian Ministry of Education (MOE) for the support and the schools that participated in this study. We also would like to acknowledge Mr. Muhamad Faizal Che Leh for his contributions in this project.

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Development of Ergonomics Furniture

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