From The Ergoweb® Learning Center

Ergonomics- Install Headlamps

Task Prior to Abatement (Description)

This is a fictitious job but reflective of common work situations on an auto assembly line.

Worker position: The worker stands adjacent to the auto assembly line.

Attach spring: The worker gets a spring and airpowered screwdriver from the bench. Two set screws, obtained from the worker’s waist pouch, are used to attach the spring to the headlight assembly. They are started with the fingers and set with the power screwdriver.

Position/secure headlamp: The worker reads the light specs from a placard on the door and gets the proper headlamp assembly. The bulb is plugged into the socket and the assembly positioned over the set screws. A hook is used to attach and hold the headlamp assembly.

Task Prior to Abatement (Illustration)


Ergonomic Risk Factor (Mechanical)

The thin handle of the wire hook produces concentrated pressure on hand tissues.

Ergonomic Risk Factor (Posture)

The body position of bending at the waist to install set screws and springs stresses the low back.

Extreme flexion of the wrist required to install the spring on the headlamp is stressful to wrist tissues.

Ergonomic Solution (Engineering Controls)

Locate the vehicle so that the headlights can be installed without bending over. This can be achieved by installing the headlights at a location where the line is elevated for work on the underside.

Provide a handle for the hook used to install the spring on the headlights. The handle should have well rounded corners and be bent thirty to sixty degrees to eliminate wrist deviation.

Ergonomic Solution (Illustration)


Armstrong, Thomas J.; Fine, Lawrence J.; Joseph, Bradley; and Silverstein, Barbara. Analysis of Selected Jobs for Control of Cumulative Trauma Disorders in Automobile Plants. Ann Arbor, Michigan: The University of Michigan, 1984.