Inter-worker variability in lower body postures during assembly line work: implications for exposure assessment.

This study evaluated inter-worker variability in lower body posture and work activity during highly-structured assembly line work. Data were collected from 79 unique assembly line workstations in an engine manufacturing plant. Because the plant utilized work teams, 4-8 workers rotated through each workstation. At least 30 min of videotape was collected from at least three workers at each workstation. A computer-assisted work sampling procedure randomly selected 200 video "freeze-frames" for each worker. Lower body posture/movement (e.g., sit, stand, walk, etc.) was determined for each frame and used to estimate the percentage of time the worker spent in various postures and activities. Chi-square analyses were performed for each workstation to assess the significance of inter-worker differences. Due to variations in individual work methods, significant differences (p <.05) were found at 57 out of 79 workstations (72%). The greatest differences occurred when workers had the option to choose between standing and sitting (significant in 8 of 8 cases; in extreme examples, sit time ranged between 0-100% on one job, and 6.5-98% on another). Studying a single worker (or "proxy") can contribute to substantial error when estimating exposures in workplace studies of ergonomic stressors, since the proxy may not be representative of all workers who perform the job. Individual measurements are preferable, particularly for jobs where workers have substantial latitude to develop individualized work methods.