HFM20321_LR.dvi


Using Ergonomic Digital Human Modeling in Evaluation
of Workplace Design and Prevention of Work-Related
Musculoskeletal Disorders Aboard Small Fishing Vessels
Enrique Álvarez-Casado,∗ Bing Zhang,∗∗ Sonia Tello Sandoval,∗∗∗ and Mondelo Pedro∗∗
∗Department d’Organizacio d’Empresses, Universitat Politecnica de Catalunya (UPC), Barcelona, spain, 08028
∗∗Centre Especific de Recerca per a la Millora i innovació de les Empresses (CERpIE), Universitat Politecnica de Catalunya
(UPC), Barcelona, Spain, 08028
∗∗∗Centro de Ergonomia Aplicada, Barcelona, Spain, 08028

Abstract

This article seeks to present methods for preventing work-related musculoskeletal disorders of Spanish
fishermen and for redesigning the workplace aboard small fishing vessels. To achieve its objective,
the research project was designed in four steps. First, the equipment and procedures for catching,
handling, and storing fish were studied. Second, the work postures of all the fishermen were simulated
and assessed by using an ergonomic digital human modeling system (ManneQuin Pro). Third, the
work environment design aboard vessels was modified on the basis of acceptable simulated work
postures to prevent repetitive movements, awkward working postures, and lower back biomechanical
stresses. In the fourth step, ergonomic design parameters were provided to vessel designers. C© 2011
Wiley Periodicals, Inc.

Keywords: Work-related musculoskeletal disorder (WSMD); Physical risk factors; Vessel ergonomic
design; Postures simulation; Work place; Digital human modeling

1. INTRODUCTION
In the past 12 months, 8.6% of workers in the EU
experienced work-related health problems: This num-
ber corresponds to 20 million persons. Meanwhile,
back problems (28%); neck, shoulder, arm, or hand
problems (19%); and stress, depression, or anxiety
(14%) are most often reported as the most serious
health problems (Eurostat, 2009). In this report, 70%

∗∗Correspondence to: (CERPIE) Research Centre for Cor-
porate Innovation, UPC (Technical University of Catalonia),
AV. Diagonal, 647 planta 10 – ETSEIB, 08028 Barcelona,
Spain. Phone: +34 93 405 44 69; e-mail: bing.zhang@
upc.edu

Received: 14 September 2010; revised 16 December 2010;
accepted 7 March 2011

View this article online at wileyonlinelibrary.com/journal/hfm

DOI: 10.1002/hfm.20321

of fishermen have been exposed to one or more fac-
tors adversely affecting physical health; this number
is only slight less than the number of workers in the
mining sector (75%). The European Foundation for
the Improvement of Living and Working Conditions
(2007)presents that almost a third (30.7%) of Spanish
workers believe that their workplace design is lacking
quality in some way. The most arduous working po-
sitions affect farmers, stockbreeders, fishermen, and
sailors in particular; in all of these professions, 15.4%
of workers carry out their work with a bent back.

In Spain, it has been concluded (Ruiz & Ledesma,
2008) that work-related musculoskeletal disorders
(WMSDs) (in particular, low back pain [LBP]) are
some of the most important problems of the fisherman
population. In fact, the official data from the Spanish
Labour Ministry about accidents in 2007 show that
WMSDs represent the main cause of accidents in fish-
ermen (more than 25% of the registered cases).

Human Factors and Ergonomics in Manufacturing & Service Industries 00 (0) 1–10 (2011) c© 2011 Wiley Periodicals, Inc. 1



Using Ergonomic DHM in Evaluation of Workplace Aboard Álvarez-Casado et al.

The term “musculoskeletal disorder” (MSD) is
used collectively for symptoms and disease of the
muscles, tendons, and/or joints. WMSDs and in-
juries occur when there is a mismatch between the
physical requirements and the physical capacity of
the human body (Taelman, Adriaensen, Spaepen,
Langereis, Gourmelon, & Van Huffel, 2006). Conse-
quently, WMSDs and injuries are caused by a combina-
tion of risk factors such as repetitive motion, excessive
physical exertion, and bad and/or awkward working
postures. Posture as a source of musculoskeletal ill-
nesses such as low back diseases have attracted the most
attention, however. Musculoskeletal problems related
to repetitive work are also connected to posture.

There are a few studies related to WMSDs in some
countries. Swedish studies on fishermen have shown
that symptoms from the musculoskeletal system are
common and that they follow a logical pattern ac-
cording to the fishing and type of working tasks
on board. During the 12 months before the study,
74% of the fishermen had experienced symptoms of
the musculoskeletal system (Torner, Blide, Eriksson,
Kadefors, Karlsson, & Petersen, 1988). The authors
found that the largest number of fishermen consid-
ered the motion of the vessel to be a major strain, not
only on the musculoskeletal system, but on the indi-
vidual as a whole. In their research of work-related
injury in New Zealand commercial fishermen, Nor-
rish and Cryer (1990) found that 139 of the 307 cases
were diagnosed as strains or sprains. Back strain (87
cases) represented almost two thirds of these and 28%
of the total injuries. This finding agrees with the find-
ing that more than one third of the injuries (121 cases)
were recorded as having occurred during lifting, low-
ering, loading, or unloading and that boxes (probably
containing fish in many cases) were specified in 28 of
these cases. The worker’s compensation for back strain
injuries was 36% of the total cost, and indicates the
importance of this injury group. Strains of the knees,
shoulders, and forearms were also common.

To quantify biomechanical stresses on the lumbar
spine during work activities of commercial crab fish-
ermen, and thus determine work task priorities for
ergonomic intervention, the continuous assessment of
back stress methodology was used to develop distribu-
tions describing the amount of time that each of the
members on a two- or three-man crabbing crew spend
at various levels of low back stress (Mirka, Shin, Kucera,
& Loomis, 2005). An observational work-sampling
technique—Posture, Activity, Tools, and Handling—

was used to describe the prevalence of awkward pos-
tures and other physical risk factors for shoulder symp-
toms among a purposive sample of 11 small-scale com-
mercial crab pot fishing crews (Kucera & Lipscomb,
2010).

LBP is a generic term for various low back dis-
eases. It has many causes, and posture is one possible
causal element (Kuorinka, 2010, website of Interna-
tional Labour organization). Epidemiological studies
have shown that physically heavy work is conducive to
LBP and that postures are one element in this process.
There are several possible mechanisms that explain why
certain postures may cause LBP. Forward bending pos-
tures increase the load on the spine and ligaments,
which are especially vulnerable to loads in a twisted
posture. External loads, especially dynamic ones, such
as those imposed by jerks and slipping, may increase
the loads on the back by a large factor. From a safety
and health standpoint, it is important to identify bad
postures and other postural elements as part of the
safety and health analysis of work in general.

This study was done in Catalunya, Spain, where there
are 1349 fishing boats, and 57% are small fishing ves-
sels. The main goal of our research was to identify and
assess the risk factors of WMSDs in fishing tasks of
Spanish fishermen and to evaluate the workplace de-
sign aboard in-shore small fishing vessels.

There are many challenges to identifying and assess-
ing the risk factors on board fishing vessels. In our
case, there are three main research problems that have
to be solved: 1) ergonomics analyses related to work-
place layout design; 2) studies of fishermen’s working
postures while catching, handling, lifting, and storing
fish; and 3) workplace redesign and construction to
prevent WMSDs on board fishing vessels.

Integration of the human factor and ergonomics in
the design and construction of fishing vessels has been
studied by many research groups (Chauvin, Le Bouar,
& Renault, 2008; Orosa & Oliveira, 2010). For instance,
personnel movement simulation has been integrated
into preliminary ship designing for testing vessel layout
suitability (Andrews, Casarosa, Pawling, Galea, Deere,
& Lawrence, 2007). The project led to improved ship
design, provided a major savings for ship operators,
improved the efficiency of the ship-designing process
by reducing time and costs, and ensured that the ves-
sel was safer and more efficient for the personnel on
board. Ergonomics research related to workstation lay-
outs and manual lifting and handling has been imple-
mented in many industrial countries. A structured job

2 Human Factors and Ergonomics in Manufacturing & Service Industries DOI: 10.1002/hfm



Álvarez-Casado et al. Using Ergonomic DHM in Evaluation of Workplace Aboard

analysis procedure was developed to assist occupational
health and safety professionals in the recognition and
evaluation of exposures to ergonomic stresses in the
workplace (Keyserling, Armstrong, & Punnett, 1991).
Additionally, a comparison between occupational in-
juries in the French sea fishing industry in the 1980s and
those of today was carried out (Chauvin & Le Bouar,
2007). This research found that catch processing and
handling caused a great number of accidents. During
these tasks, fishermen have to cope with two main risks:
getting cut or pricked, and making an excessive physical
effort and/or awkward movement.

Digital human modeling has been applied in er-
gonomics design and analyses for a long time. A
method for conducting workplace assessments in
the digital environment was proposed for preventing
WMSDs (Chang & Wang, 2007). By integrating dy-
namic simulation and ergonomics evaluation, digital
human modeling enables the system designer to vi-
sualize and improve workplace design in the digital
space. The method has been applied to evaluate au-
tomobile assembly tasks. The distinct advantages of
integrating the ergonomic analysis model with the dig-
ital human modeling include 1) the ability to perform
ergonomic assessments in the early design process and
2) improved communication of both ergonomic con-
cerns and design alternatives. A comparative study
was made of digital human modeling simulation re-
sults and their outcomes in the real world (Lamkull,
Hanson, & Ortengren, 2009). The results of that
study show that ergonomic digital human modeling
(EDHM) tools are useful for providing designs of
standing and unconstrained working postures. How-
ever, Using EDHM tools to simulate work processes
and postures for purposes of risk prevention has not
been adequately done.

This article is aimed at presenting methods for im-
proving health and safety in the Spanish fishing sector,
where occupational hazard rates are extremely high. To
obtain its objective, the research project was designed
with the following steps: First of all, equipment and
procedures for catching, handling, storing, and pro-
cessing fish were studied. Second, the work postures
of all the fishermen were simulated and evaluated by
using a digital human modeling system (ManneQuin
PRO, used by the laboratory of CERpIE, UPC). Third,
based on acceptable work postures of fishermen sim-
ulated by ManneQuin PRO, the modifications of ves-
sel design and construction relevant to preventing low
back biomechanical stresses and repetitive movements

was recommended. The digital human modeling sys-
tem applied in this project has been effective in terms
of simulating and evaluating fishermen’s work postures
and providing ergonomic design parameters for fishing
vessel designers.

2. METHODS
Manual handling involves the movement of heavy
loads by hand or bodily force, and should be avoided
when possible. Work-related upper limb disorders arise
mainly from performing repetitive actions. If avoid-
ance is not possible, risk of injury must be reduced as
much as possible by actions that include 1) improving
workplace design so that less movement is needed; 2)
modifying the load by making it lighter or easier to
hold; and 3) training workers in good practices such
as proper handling techniques (Agilent Technologies,
Inc., 2007).

To improve on board workplace design, one must
first simulate the work process and the work postures
of the fishermen. Figure 1 depicts the work flowchart
for the ergonomic redesign of the workplace aboard
fishing vessels.

In this research study, the digital fishermen have
been built with ManneQuin PRO. ManneQuin PRO
human modeling programs have been the most suc-
cessful in the world, with thousands of users since the
original ManneQuin program was introduced in 1990.
Two important features of ManneQuin Pro are 1) er-
gonomically correct human figures for a range of ethnic
groups, percentiles, and body types and 2) simulation
of lifting, pushing, and pulling by adding forces and
torque in any direction on any body part.

ManneQuin PRO is a PC-based, three-dimensional
(3D) human modeling software package that helps per-
form basic analysis during the design, validation, and
communication stages of any space design project. It
features various biomechanical tools that may be used
to enhance analyses or validate new or existing human
centered designs. Moreover, ManneQuin PRO is con-
veniently equipped with the Revised National Institute
of Occupational Safety and Health Lifting Equation for
lifting task analysis. If properly used, this formulation
can provide a recommended lifting weight for a spec-
ified activity. The multiple anthropometric databases
for creating mannequins ensure that the space fits the
desired population characteristics.

Human Factors and Ergonomics in Manufacturing & Service Industries DOI: 10.1002/hfm 3



Using Ergonomic DHM in Evaluation of Workplace Aboard Álvarez-Casado et al.

Figure 1 Work flowchart of ergonomic redesign of work areas aboard fishing vessel.

Figure 2 Purse seining fishing method.

2.1. Risk Factor Identification and
Assessment of Working Aboard Small
Shipping Vessels

There are several fishing methods for in-shore fishing
vessels. Purse seining is the general method of encir-
cling a school of fish with a large net. The net is then
drawn together underneath the fish (pursed) so that
they are completely surrounded. It is one of the most
aggressive methods of fishing and aims to capture large,
dense shoals of mobile fish such as tuna, mackerel, and
herring (Fishing on line). Figure 2 describes the steps
used in purse seine fishing.

In purse seine fishing inshore, the following tasks are
executed:

1. Pulling the net through the water to make a
type of wall;

2. Gathering up the net;

3. With scoop nets, placing fish into boxes;
4. Arranging fish into empty boxes until boxes

are full;
5. Placing ice on fish;
6. Collecting fish from the floor and placing them

into boxes;
7. Carrying boxes to pallet and stacking; and
8. Lowering boxes from ship at port.

After getting permission, we used a video camera
and a digital camera to record the working tasks aboard
one fishing vessel. Other data related to work organiza-
tion and time shifting was also collected during three
days of observation on board. The fishing boat leaves
at 9 o’clock in the evening and comes back to down-
load fish at approximately 6 o’clock the morning of the
next day. The first step of our research was to identify
and assess risk factors in working aboard small fishing

4 Human Factors and Ergonomics in Manufacturing & Service Industries DOI: 10.1002/hfm



Álvarez-Casado et al. Using Ergonomic DHM in Evaluation of Workplace Aboard

Figure 3 Typical hazardous postures on board fishing vessels. Left to right: Trunk bending forward/backward; sideways;
twisting; low back and lower extremities; and upper arm posture - EN 1005-4:2002(E).

Figure 4 Examples of occupational risks in the work areas and tasks aboard small fishing vessels.

vessels, based on videos and images collected on board.
The hazard parameters and the cause of the parame-
ters of all the working postures (including postures of
catching, pushing, lifting, and pulling) were identified
and assessed.

Figure 3 displays the typical hazard postures aboard
fishing vessels found in the analysis: trunk bending
(forward, backward, and sideways); twisting (lower

back and lower extremities); and upper arm posture
- EN 1005-4: 2002 (E). Figure 4 shows some exam-
ples found aboard small fishing vessels of work areas
and tasks with high occupational risks. In Figure 4a,
the fishermen place empty boxes (for the incoming
fish) on top of the full boxes. Figure 4b shows how,
after placing the fish in the boxes, the fishermen must
squat on the floor to pick up the remaining fish and put

Human Factors and Ergonomics in Manufacturing & Service Industries DOI: 10.1002/hfm 5



Using Ergonomic DHM in Evaluation of Workplace Aboard Álvarez-Casado et al.

TABLE 1. Identification Risks from Working Postures

Task a: Arrange the Fish Inside the Boxes Task b: Pick the Fish up from the Floor Task c: Carry the Boxes for Stacking

Range Critical
for 5%

Range Critical
for 95%

Range Critical
for 5%

Range Critical
for 95%

Range Critical
for 5%

Range Critical
for 95%

High frequency
over 60◦

High frequency
over 60◦

Squat to work Squat to work Flexion of the
torso 48◦

Flexion of the
torso 57◦

Flexion of the
torso
between 20◦

and 60◦ with
high
frequency
and over 60◦

is NOT
ACCEPTABLE

Flexion of the
torso
between 20◦

and 60◦ with
high
frequency
and over 60◦

is NOT
ACCEPTABLE

FORBIDDEN FORBIDDEN Flexion of the
torso
between 20◦

and 60◦ with
high
frequency is
NOT
ACCEPTABLE

Flexion of the
torso
between 20◦

and 60◦ with
high
frequency is
NOT
ACCEPTABLE

Flexion of the
upper arm
89◦

Flexion of the
upper arm
97◦

Flexion of the
upper arm
90◦

Flexion of the
upper arm
97◦

NOT
ACCEPTABLE

NOT
ACCEPTABLE

Flexion of upper
arm in 80◦

with high
frequency in
moving is
NOT
ACCEPTABLE

Flexion of upper
arm in 80◦

with high
frequency in
moving is
NOT
ACCEPTABLE

them in the boxes. This squatting posture is completely
forbidden according to International Organization for
Standardization (ISO) standards. Figure 4c presents a
fisherman manually carrying and stacking boxes one
on top of the other. Table 1 depicts the risk factors for
each of these three tasks.

2.2. Simulation of Bad or Awkward
and Acceptable Working Postures

After identifying risk factors, the next step was to sim-
ulate bad working postures and present acceptable
working postures, with the help of our digital fish-
ermen. The practical limit of arm reach, for exam-
ple, is not the sole consequence of arm length; the
limit is also affected by shoulder movement, partial
trunk rotation, possible bending of the back, and the
function to be performed by the hand (Sanders &
McCormick, 1992). Therefore, it is difficult to simulate
all the possible interactions by various body segments
of the men while they are fishing.

The multiple anthropometric databases for creat-
ing mannequins ensure that the space fits the de-
sired population characteristics. According to statis-
tics from December 2007, there are 50,309 fishermen
in Spain (Carmona, 2003). Among these fishermen,
4% are women. 5% and 95% percentiles of Span-
ish fishermen (men) were selected. The anthropo-
metric data of the ergonomics software (ManneQuin
Pro) had been semi-updated. In other words, only
weight and height in the original anthropometry data
were updated to the ones of Spanish fishermen. Other
anthropometry data, such as sitting height, should
breath, and so forth, were applied based on the French
population.

Other biomechanical and anthropometric data were
updated according to these two parameters. Dur-
ing simulation of working postures, differences in
degree of physical effort due to variations in body
heights are noted, to better describe actual conditions
for workers of different sizes working in the same
workplace.

6 Human Factors and Ergonomics in Manufacturing & Service Industries DOI: 10.1002/hfm



Álvarez-Casado et al. Using Ergonomic DHM in Evaluation of Workplace Aboard

TABLE 2. Findings from Analysis Using EDHM in Simulating Three Task on Board Small Fishing Vessels

Human Factors and Ergonomics in Manufacturing & Service Industries DOI: 10.1002/hfm 7



Using Ergonomic DHM in Evaluation of Workplace Aboard Álvarez-Casado et al.

Figure 5 An idea to avoid picking up fish from the floor. The simple structure will help to correctly place the fishin the
boxes.

2.3. Inputting 3D Geometric Data
of Designed Fishing Vessel
into ManneQuin Pro

The 3D geometric data of the designed fishing ves-
sel were imported into ManneQuin Pro, and all
the digital fishermen were placed in a 3D fish-
ing vessel to simulate real-life work conditions on
board.

3. RESULTS
By using an EDHM system and simulating all on board
work postures, we found multiple risk factors aboard
fishing vessels. In contrast, we also found solutions for
redesigning the work areas on board to prevent occu-
pational hazards in fish collection, processing, trans-
portation, and storage.

3.1. Redesigning Work Areas Aboard
Shipping Vessels Based on Acceptable
Working Postures

In this article we present our research findings in the
tables. Table 2 presents the findings of our analysis of
three tasks aboard small fishing vessels. Task A is to
arrange the fish in boxes until the boxes are full. Task
B is to collect the fish from the floor and put them into
the boxes, Task C is to transport and stack the boxes on
pallets.

As we can see from Task C, the ergonomic digital
fishermen have been simulated in bad postures when
transporting and stacking boxes on pallets; accordingly,
the upper body–including the upper arm and neck–is
in hazard red. In other words, the upper body is in
red, which indicates that it is in a posture with risk

of developing an MSD. After analysis of risk factors,
solutions for workplace redesign are provided with re-
gard to work surface height. Acceptable and good pos-
tures have also been simulated based on the redesigned
workplace.

3.2. Recommendation for Ergonomics
Workplace Design

In our simulation of the workplace aboard fishing ves-
sels, we found that there was inadequate foot clearance
in the current workplace when fish boxes were being
stacked. Foot clearance is an important design parame-
ter if fishermen are to maintain good working postures;
therefore, we made some recommendations in connec-
tion with the design of the workplace aboard fishing
vessels. To avoid picking up fish from the floor and
working on one’s knees, we have designed a fish col-
lecting table, which is presented in Figure 5. Figure 5
shows how the workplace can be redesigned so as to
avoid the need to pick up fish from the floor. With this
design, the fish will fall directly into the boxes and not
onto the floor.

4. CONCLUSION
In this study, we have found that the work areas aboard
a fishing vessel present typical examples of a work en-
vironments that pose risks to workers regarding the
development of WMSDs. The risk factors of MSD have
to be controlled at the source, and the risks have to be
minimized by such means as the design of safe work
systems. Consequently, the current on board work-
place needs to be redesigned from an ergonomic and
human-centered point of view. A suitable work desk
is needed for many on board tasks if the fishermen

8 Human Factors and Ergonomics in Manufacturing & Service Industries DOI: 10.1002/hfm



Álvarez-Casado et al. Using Ergonomic DHM in Evaluation of Workplace Aboard

are to have good working postures. The size of the on
board workplace is limited, however. Using devices for
collecting fish and transporting boxes for stacking is
difficult. Therefore, there is a need for further innova-
tion and redesign of the on board workplace to reduce
the risk factors involved.

In contrast, we also have found EDHM for simu-
lating the workplace and work postures to be an ef-
fective tool for assessing the workplace and preventing
WMSDs aboard fishing vessels. We have made sev-
eral recommendations to the final vessel designer as to
how to redesign the workplace to reduce hazards and
risk factors involving manual handling operations in
the Spanish fishing industry. With regard to computer
software, additionally, we have found that the interface
and feedback display of the EDHM system has to be
improved in the future.

ACKNOWLEDGMENT
We thank Judith Mayers for correcting the English in
this article.

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