Ergonomics Study of Maintenance Pit Operations
Corus Rail
Background
Stewarts Lane Depot is located in Battersea, London. It provides a number of train sheds to accommodate over 14 trains for maintenance work. Following various changes to the rolling stock being maintained, maintenance operations and concerns about health & safety, a feasibility study was launched to assess how the height between the maintenance pit base and the running rail could be increased. The existing height of 1200mm was assessed as too low for effective maintenance operations. An ergonomics study was required to assess the various maintenance tasks and how varying heights in the pit would accommodate them and to assess how other improvements could be made inside the pit.
Project
We were asked to complete an ergonomic study on the current pit depth with the current depth being assessed as operationally too low for their maintenance staff to complete their work safely and effectively. Four design options were proposed and these were investigated by our Human Factors consultants.
The aim of the study was to examine the ergonomic feasibility of alternative approaches to increasing the height of the maintenance pit, concentrating on the main operational tasks including Shafenburg Check, Brake Pad Change, Earth Return Unit Change, Train Exam, Fan Change, Motor Oil Change and Pimm Change
Implementation
We undertook observational studies to understand the maintenance tasks conducted in the pits. We then conducted Human Modelling SAMMIE CAD Analysis using 5th%ile to 95th%ile human models to assess vision, reach and postural analysis and a biomechanical risk assessment of working postures.
User interviews to gain an understanding of the detailed task requirements along with interviews with Safety Representative and review of documentation such as the accident book. We liaised with the Project Engineers to assess the constructability of the design solutions.
Outcomes
A solution was offered for the most suitable pit height, based on the four possible solutions proposed by Corus. This included detailed biomechanical analysis on postural strains/limitations and possible risks to health and safety.
Additional solutions were also offered including:
- Inclusion of additional fold-own shelves to allow some users to elevate themselves or store tools should they wish to do so.
- Pit lighting maintenance.
- Provision of head torches and tool belts, regulations on bump caps.
- How to make full use of existing job aids within the pit and advice on improvements to those currently used.
- A recommendation for a height adjustable pit floor, through use of a trolley, which can be adjusted on an individual basis.