U.S. patent application number 16/897720 was filed with the patent office on 2020-09-24 for system and method for monitoring safety and productivity of physical tasks.
The applicant listed for this patent is One Million Metrics Corp.. Invention is credited to Aditya Bansal, Mijael Damian, Jeff Doong, Haytham Elhawary, Matthew Glazer, Evan Roche, Derek Squires, Marina Teper.
Application Number | 20200297250 16/897720 |
Document ID | / |
Family ID | 1000005073969 |
Filed Date | 2020-09-24 |
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United States Patent
Application |
20200297250 |
Kind Code |
A1 |
Elhawary; Haytham ; et
al. |
September 24, 2020 |
SYSTEM AND METHOD FOR MONITORING SAFETY AND PRODUCTIVITY OF
PHYSICAL TASKS
Abstract
Methods and systems for monitoring workplace safety and
evaluating risks is provided, the method comprising receiving
signals from at least one wearable device, identifying portions of
the signals corresponding to physical activities, excerpting the
portions of the signals corresponding to the physical activities,
and calculating risk metrics based on measurements extracted from
the excerpted portions of the signals, the risk metric indicative
of high risk lifting activities.
Inventors: |
Elhawary; Haytham; (New
York, NY) ; Bansal; Aditya; (White Plains, NY)
; Doong; Jeff; (Jersey City, NJ) ; Glazer;
Matthew; (Long Beach, NY) ; Roche; Evan; (New
York, NY) ; Damian; Mijael; (New York, NY) ;
Squires; Derek; (Shirley, NY) ; Teper; Marina;
(New York, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
One Million Metrics Corp. |
New York |
NY |
US |
|
|
Family ID: |
1000005073969 |
Appl. No.: |
16/897720 |
Filed: |
June 10, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16524737 |
Jul 29, 2019 |
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16897720 |
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15594177 |
May 12, 2017 |
10674965 |
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16524737 |
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14660578 |
Mar 17, 2015 |
9833197 |
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15594177 |
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62711488 |
Jul 28, 2018 |
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62786597 |
Dec 31, 2018 |
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62335070 |
May 12, 2016 |
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61953934 |
Mar 17, 2014 |
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62110630 |
Feb 2, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 5/6823 20130101;
A61B 5/1118 20130101; A61B 5/6838 20130101; A61B 5/1126 20130101;
A61B 5/1116 20130101 |
International
Class: |
A61B 5/11 20060101
A61B005/11; A61B 5/00 20060101 A61B005/00 |
Claims
1. A computer-based method for generating a log of activity of
workers comprising: receiving, at a processor, a first signal from
a first wearable device indicative of physical characteristics of
the first wearable device over time; identifying, in the first
signal, a plurality of signal segments corresponding to at least
one of several expected physical activities; correlating each of
the plurality of signal segments with a corresponding physical
activity; and generating a log of physical activity performed by a
user wearing the first wearable device.
2. The computer-based method of claim 1 further comprising:
receiving, at the processor, an indication of a location of the
first wearable device; and selecting the several expected physical
activities based on physical activities expected at the location of
the first wearable device.
3. The computer-based method of claim 1 further comprising
recording an indication of a location of the first wearable device
in the log of physical activity.
4. The computer-based method of claim 1 further comprising:
determining, at the processor, an indication of a location of the
first wearable device, wherein the indication of location of the
first wearable device is an indication of location relative to a
second wearable device associated with a second user or a location
of a piece of equipment; and triggering an alert when the location
of the first wearable device is within a threshold distance of the
location of the second wearable device or the piece of
equipment.
5. The computer-based method of claim 4 further comprising
recording the alert and an identity of the second user associated
with the second wearable device in the log of physical
activity.
6. The computer-based method of claim 4, wherein the piece of
equipment is a moving piece of equipment, and wherein the method
further comprises detecting a collision with the moving piece of
equipment and triggering an alert to a third party indicating that
the collision has occurred.
7. The computer-based method of claim 1 further comprising:
receiving, at the processor, an indication of a location of the
first wearable device; identifying a permissible location within
which the user is permitted to travel; and triggering an alert when
the location of the first wearable device is outside the
permissible location.
8. The computer-based method of claim 1 further comprising:
receiving, at the first wearable device, a signal from a second
wearable device associated with a second user, and wherein a
characteristic of the signal indicates a distance between the first
wearable device and the second wearable device, and triggering an
alert when the distance between the first wearable device and the
second wearable device is less than a threshold distance.
9. The computer-based method of claim 8 further comprising
recording the alert and an identity of the second user associated
with the second wearable device in the log of physical
activity.
10. The computer-based method of claim 9 further comprising
determining a length of time during which the distance between the
first wearable device and the second wearable device is less than
the threshold distance and recording the length of time in the
log.
11. A computer-based method for generating a log of activity of
workers, the method comprising: receiving, at a processor, a first
signal from a first wearable device indicative of physical
characteristics of the first wearable device over time; receiving,
at the first wearable device, a signal from a second wearable
device associated with a second user, and wherein a characteristic
of the signal indicates a distance between the first wearable
device and the second wearable device, and generating a first log
of physical activity performed by a first user wearing the first
wearable device, the log including a record of times at which the
distance between the first wearable device and the second wearable
device is less than a threshold distance.
12. The computer-based method of claim 11 further comprising, upon
a determination that the first user has a contagious disease,
identifying, in the first log, times prior to the determination in
which the first wearable device was within a threshold distance of
the second wearable device.
13. The computer-based method of claim 12 further comprising
providing, to an employer, a report from the first log indicating
proximity between the first wearable device and the second wearable
device at times identified.
14. The computer-based method of claim 11 further comprising
triggering an alert when a current location of the first wearable
device is within a threshold distance of the second wearable
device.
15. The computer-based method of claim 14 further comprising
recording an identity of the second user in the first log when the
first wearable device is within the threshold distance of the
second wearable device.
16. The computer-based method of claim 14 further comprising
recording a length of time for which the first wearable device is
within the threshold distance of the second wearable device.
17. The computer-based method of claim 11 wherein the first signal
further indicates a work zone for the first user, and wherein the
method further comprises generating an alert when the first user
and the second user are determined to be in overlapping work
zones.
18. The computer-based method of claim 17, further comprising:
receiving, at the processor, a plurality of additional signals
indicative of physical characteristics of corresponding additional
wearable devices over time; identifying, in each of the additional
signals, a plurality of signal segments corresponding to work zones
at associated times; identifying instances in which a plurality of
wearable devices are within a single work zone simultaneously; and
generating a report of locations corresponding to work zones having
multiple instances in which a plurality of wearable devices are
within a single work zone simultaneously.
19. A computer-based method for generating a log of activity of
workers comprising: receiving, at a processor, a first signal from
a first wearable device indicative of physical characteristics of
the first wearable device over time; identifying, in the first
signal, a plurality of signal segments corresponding to at least
one of several expected physical activities; correlating each of
the plurality of signal segments with a corresponding physical
activity; generating a log of physical activity performed by a
first user wearing the first wearable device; receiving, at the
first wearable device, a signal from a second wearable device
associated with a second user, and wherein a characteristic of the
signal indicates a distance between the first wearable device and
the second wearable device; triggering an alert when the location
of the first wearable device is within a threshold distance of the
second wearable device; and recording the alert, an identity of a
second user associated with the second wearable device, and a
length of time during which the first wearable device is within the
threshold distance of the second wearable device in the log of
physical activity.
20. The computer-based method of claim 19 further comprising:
receiving, at the processor, an indication that the first user has
a contagious disease; and identifying, in the log, a listing of
identities of secondary users associated with any secondary devices
that had been within the threshold distance of the first wearable
device.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/524,737, filed Jul. 28, 2019, which claims
the benefit of U.S. Provisional Patent Application No. 62/711,488,
filed Jul. 28, 2018, and claims the benefit of U.S. Provisional
Patent Application No. 62/786,597, filed Dec. 31, 2018. U.S. patent
application Ser. No. 16/524,737 is also a continuation in part of
U.S. patent application Ser. No. 15/594,177, filed May 12, 2017
which claims the benefit of U.S. Provisional Patent Application No.
62,335,070, filed May 12, 2016, and is a continuation in part of
U.S. patent application Ser. No. 14/660,578, filed Mar. 17, 2015
which claims the benefit of U.S. Provisional Patent Application No.
61/953,934, filed Mar. 17, 2014, and U.S. Provisional Patent
Application No. 62/110,630, filed Feb. 2, 2015, the contents of
each of which are incorporated by reference herein in its
entirety.
FIELD OF THE INVENTION
[0002] The systems and methods relate to monitoring workplace
safety and productivity and generating recommendations to improve
such safety and productivity.
BACKGROUND
[0003] In industries that require physical manipulation of objects
or people, such as material handling, patient handling,
manufacturing, or construction, workers often perform a variety of
manual tasks such as lifting loads, moving loads from one location
to another, pushing and pulling carts or trolleys, complex assembly
and manipulation of components using specific motions and using
vibration and impact tools. Often these motions require an intense
physical effort, and therefore the repetition of these tasks over
time can cause fatigue and injury.
[0004] Wearable technology has been used extensively in the
consumer space to quantify, for example, the number of steps taken,
distance traveled, length and quality of sleep and other metrics,
but wearable technology has not been able to consistently evaluate
safety metrics in the materials handling industry.
[0005] Many risks associated with material handling workers exist,
including repetitive stress injuries based on extended physical
effort over prolonged periods of time.
[0006] Current solutions are mostly limited to physical inspection
by specialists, since there is a lack of effective tools to predict
when lifting posture is incorrect, or when fatigue results in a
risky or dangerous change of posture or non-ergonomic lifting
techniques when performing tasks. Typically, specialists inspect
the workplace and observe tasks, or review video footage provided
by the employer. In either case, inspection is typically performed
over only a limited period of time, usually 5-60 minutes. Without
effective tools, employers (and workers themselves) have difficulty
predicting and preventing injury.
[0007] Further, while workers are taught correct material handling
techniques, such techniques are not tailored to the strengths of a
particular worker. Different workers can do a particular task in
multiple ways because of varying body types and abilities. Better
monitoring of task performance incorporating information about the
particular worker involved may allow for customized training
techniques.
[0008] Further, there is a lack of productivity measuring tools for
individual workers, as it is rarely possible to measure in
real-time the number and quality of tasks a specific worker is
performing including their speed and variation over time. This
information could allow managers to optimize productivity or to
devise novel forms of incentives based on productivity.
[0009] Finally, tasks are typically divided among the workers based
partially on physical ability. However, the physical ability to do
a specific task is determined based on visual observation without
any detailed insights on the actual motion of a worker's body.
Quantifying body motion can help supervisors factor such
information into task and shift assignments. Therefore, additional
information related to the aspects of task performance that
increase injury risk can inform the design of a workplace, design
of shifts, and assignment of tasks.
[0010] Existing systems for analyzing the safety and productivity
of material handling tasks by analyzing motion have limited
real-world applications due to inherent limitations.
[0011] Motion detection based platforms, such as optical systems
using complex cameras and sensors, are expensive and are of limited
use in a warehouse setting as they require line of sight which is
not always possible in crowded warehouse or factory
environments.
[0012] Electromagnetic based motion sensor systems produce errors
when they are close to ferromagnetic materials often present in
industrial settings, are expensive and typically require cabling
from sensors to processing units, making their continued use
impractical in a warehouse setting.
[0013] Existing devices provide very limited motion information and
are typically bulky and impractical. Existing systems cannot
extract adequate information to fully implement risk models, and
typically require manual input of risk variables that cannot be
measured by the device alone.
[0014] Further, in systems where devices are assigned to users for
tracking purposes, the devices are typically stored at an employer
facility along with devices associated with or assigned to other
workers. It is difficult to ensure that a particular user is using
the correct device, and that the device is assigned to that
worker.
[0015] Further, where workers may be tracked, feedback is not
always provided, and where feedback is provided, it is not always
immediate or provided in a useful form. Further, feedback may not
prevent workers from performing dangerous tasks, even where such
feedback is received. For example, a worker may receive a warning
that it is dangerous to drive a forklift without a helmet, but such
a system may not know when the worker is attempting to drive a
forklift or prevent the user from doing so if an attempt is
detected.
[0016] Further, where worker activities may be used to provide
feedback, such systems cannot generate insight into longer term
injuries, beyond detecting that a single action is potentially
dangerous.
[0017] Finally, none of the tracking systems described can leverage
the tracking information to improve morale by encouraging and
incentivizing safe practices or to reduce costs by incentivizing
and confirming practices that reduce insurance premiums.
[0018] There is a need for a fully automatable system and method
that can monitor physical activity of individual workers and
evaluate safety and productivity both for individuals and for a
workspace as a whole. There is a further need for a platform that
can incorporate such evaluations into recommendations for improving
the technique of individual workers and physical characteristics of
the workplace environment.
[0019] Finally, there is a need for such a platform that can
leverage data generated to improve morale, ensure safety, and
reduce employer costs.
SUMMARY
[0020] A computer based method is provided for indicating risk
during physical activities, in which the method receives a first
signal from a wearable device generated from dynamic activity of
the wearable device over time. The method then identifies, from the
first signal, an initiation time for a first physical activity
performed by a wearer of the wearable device, and calculates
measurements of the wearer for the time period during the first
physical activity.
[0021] The method then repeats the first steps of the method to
identify and calculate measurements for a plurality of additional
physical activities. The method then calculates an activity risk
metric for each identified physical activity from a risk model
based on the measurements of the wearer during the corresponding
physical activity. The risk metric is indicative of a risk level
for the corresponding physical activity. The method then separately
calculates a cumulative risk metric indicative of a risk level from
multiple physical activities over time.
[0022] Once both the activity risk metric for a given activity and
a cumulative risk metric over time are calculated, the method
generates an alert only if the cumulative risk metric is above a
cumulative risk threshold and the activity risk metric for a most
recent physical activity is above an activity risk threshold.
[0023] The cumulative risk metric may be for a sliding window of
time immediately prior to the calculation of the activity risk
metric. The cumulative risk metric may be a risk frequency metric,
which would be a measure of the frequency of the activity risk
metric being above the activity risk threshold during the sliding
window of time. In some embodiments, the cumulative risk metric is
a measure of rest periods between instances of the activity risk
metric being above the activity risk threshold.
[0024] In some alternative embodiments, the cumulative risk metric
is a measure of the number of physical activities performed during
the sliding window.
[0025] In some embodiments, the cumulative risk threshold changes
over the course of a day or over a longer period of time.
[0026] In some embodiments, the cumulative risk metric is based on
kinematic variables including at least one of back bending angle
and cumulative trunk loading. The cumulative risk metric may then
be based on a time integration of kinematic variables over the
window of time. Further, the cumulative risk metric may be based on
variables different than those on which the activity risk metric is
based.
[0027] In some embodiments, the design of a job assigned to the
wearer may be modified based on the cumulative risk metric
associated with the wearer. As one example, if the cumulative risk
metric is above the cumulative risk threshold for a specified
amount of time, the design of the job may be modified to require
the wearer to utilize assist equipment.
[0028] The wearable device utilized in such methods may be worn or
mounted at the user's hip, and the measurements calculated include
measurements of a user's back inferred from movement of the user's
hip detected by the wearable device. Further, movement of the
user's hip may be detected by an accelerometer, a gyroscope, and an
altimeter.
[0029] Also provided are methods for incentivizing risk reduction
during physical activities. In such an embodiment, the method may
receive a first signal from a wearable device generated from
dynamic activity of the wearable device over time and identify an
initiation time for a first physical activity of a first category
of physical activity performed by a wearer of the wearable
device.
[0030] Once the initiation time for the first physical activity is
detected, the method may calculate measurements of the wearer for a
time period during the first physical activity from a first signal
segment of the first signal for a time period following the
initiation time.
[0031] The method may then generate a payment for the wearer at a
calculated rate associated with the first category of physical
activity, the calculated rate based on a base payment rate modified
by a risk score associated with the wearer of the wearable device.
Both the risk score and the base payment rate are specific to the
first category of physical activity.
[0032] Either before or after such payment, the method would
calculate an activity risk metric from a risk model based on the
measurements of the wearer for the time period during the first
physical activity, the risk metric being indicative of a risk level
of the execution of the physical activity by the wearer. The
results of this calculation would then be used to modify the risk
score of the wearer associated with the first category of physical
activity.
[0033] The method would then be repeated to identify additional
physical activities of the first category of physical activity and
generate payments at a calculated rate associated with the first
category of physical activity for each repetition based on the
modified risk score at the time of the payment.
[0034] In some embodiments, the identification of the initiation
time of the physical activity is directly from the first signal,
and is by either the wearable device or by a server in
communication with the wearable device. In other embodiments, the
identification of the initiation time is by the wearer scanning a
code associated with the physical activity. For example, if the
physical activity is a lifting activity, the code scanned is on a
box to be lifted by the wearer.
[0035] In still other embodiments, the identification of the
initiation time is by a server in communication with the wearable
device, where the category is identified based on a log of activity
associated with the wearer and stored at the server.
[0036] In some such embodiments, the first category of physical
activities is one of several categories of physical activity, each
of which is associated with distinct base payment rates and risk
scores. Accordingly, a modification of a risk score for a category
of physical activity would affect only that risk score, and not the
corresponding scores for other categories of physical
activities.
[0037] In some embodiments, a base risk score is established for
the first category of physical activity prior to the first physical
activity, and the base risk score is modified upon the calculation
of an activity risk metric indicative of a high risk physical
activity to reduce the calculated rate for future payments. The
risk score is similarly modified upon the calculation of an
activity risk metric indicative of a low risk physical activity to
increase the calculated rate for future activities.
[0038] In some embodiments, a cumulative risk score is also
calculated, indicative of a risk level from multiple physical
activities over time. In such an embodiment, the a cumulative
modification of the risk score may be applied to reduce the
calculated rate when the cumulative risk metric is above a
cumulative risk threshold, and that modification may be removed
when the cumulative risk metric returns below the cumulative risk
threshold.
[0039] In some embodiments, a bonus payment may be applied to a
wearer's account if the cumulative risk metric stays below the
cumulative risk threshold for a defined period of time.
[0040] Also provided is a method for evaluating results of physical
activities of workers. Such a method may comprise receiving a first
signal from a wearable device indicative of physical
characteristics of the wearable device over time and identifying a
plurality of signal segments each corresponding to at least one of
several expected categories of physical activities. Each such
signal segment may then be correlated with a corresponding category
of physical activity.
[0041] An activity risk metric is then generated and associated
with each signal segment, and a log of physical activity performed
by the user wearing the wearable device is generated. The log
defines the category of physical activity, the activity risk
metric, and the time for each signal segment evaluated.
[0042] In some embodiments, the log may comprise a complete record
of raw data recorded at the wearable device or a complete record of
any calculated angles and metrics generated by the device. In other
embodiments, the log may define kinematic variables, temperature,
air pressure, and height measurements and changes at the time of
the associated signal segment. Similarly, it may further define
environmental variables or location drawn from sensors located in
the environment in which a corresponding physical activity
occurs.
[0043] The method may further comprise identifying, in the first
signal, an injury to a wearer, and may then provide to an employer
a segment of the log corresponding to a time period immediately
preceding the injury.
[0044] Also provided is a system for assigning a wearable device to
a user, the system comprising a plurality of wearable devices to be
assigned to a plurality of users and a plurality of docking
locations for docking the wearable devices. Each of the docking
locations is then provided with an indicator.
[0045] Each indicator identifies an assigned identity for the
wearable devices docked at the corresponding docking location, and
when a wearable device is placed at a particular docking location,
the wearable device is reprogrammed to correspond to the identity
identified by the corresponding indicator.
[0046] In some embodiments, the wearable device is assigned to a
user has an indicator programmed to indicate a drop off location to
which the device must be returned, and the drop off location is
selected by the system from a set of unoccupied locations.
[0047] In some embodiments, the assigned identity corresponds to a
particular user to whom the corresponding wearable device is
assigned.
[0048] The assigned identity may take the form of a scannable code
such that when a user selects a wearable device, they scan the code
with a secondary device, thereby assigning the device to
themselves.
[0049] Also provided is a method for updating insurance premiums
for workers. The method comprises associating a risk score with a
worker, receiving a signal from the wearable device generated from
dynamic activity of the wearable device over time, and identifying
an initiation time for a first physical activity of a first
category of physical activity performed by the worker.
[0050] The method then defines a signal segment corresponding to
the first physical activity and calculates measurements of the
worker for the time period during the first physical activity from
the signal segment. The method then calculates an activity risk
metric from a risk model based on the measurements of the first
worker during the time period, the metric being indicative of a
risk level of the execution of the physical activity by the
worker.
[0051] The method then repeats the detection and analysis to
identify and evaluate several physical activities. The method then
modifies the risk score of the worker based on the activity risk
metric calculated and calculates an insurance premium for the
worker based on the risk score.
[0052] In some embodiments, the worker is a member of a group of
workers, and each worker in the group is assigned an independent
risk score. The method then calculates and modifies risk scores for
each worker and calculates an insurance premium for the group based
on the individual risk scores of the workers.
[0053] In some embodiments, the method comprises calculating a
cumulative risk metric indicative of a risk level from multiple
physical activities over time and modifies the risk score of the
worker based on the cumulative risk metric.
[0054] Typically, the risk score is a predictive metric for
predicting whether the group has a high probability of incurring an
injury. In some embodiments, the insurance premium may be
calculated based at least partially on cumulative baseline risk for
a set of tasks performed by the worker.
[0055] Also provided is a method for calibrating a wearable device,
the method comprising determining that an actual physical posture
or physical activity of a user wearing the wearable device
corresponds to a known physical posture or physical activity,
receiving a first signal from the wearable device generated from
dynamic activity of the wearable device over time, identifying a
calibration signal segment corresponding to an expected pattern for
a calibration activity, and identifying a device location relative
to the user based on a variance between the calibration signal
segment and the expected pattern. For example, the calibration
activity may be walking.
[0056] In some embodiments, the device location is a side of the
user's body or a height relative to the user's hips. The device
location may also be an offset relative to a user's hip indicating
that the device is forwards or backwards of the user's hip. If the
method determines that the wearable device is improperly
positioned, the method may alert the user to the same.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 illustrates a physical environment for implementing a
method for monitoring safety;
[0058] FIG. 2A is a schematic for a sensor and sensor packaging for
use in implementing the method;
[0059] FIGS. 2B-D show a sensor packaging containing a clip for
fixing the sensor to a user;
[0060] FIG. 3A is a flowchart illustrating a method for monitoring
safety;
[0061] FIG. 3B is a plot illustrating high risk postures over time
for a worker;
[0062] FIG. 3C is a flowchart illustrating a method for monitoring
safety;
[0063] FIG. 3D is a flowchart illustrating a method of generating
an activity log;
[0064] FIGS. 4A-C show systems in which the sensor and sensor
packaging may be implemented;
[0065] FIG. 5 illustrates a method for enforcing safety rules;
[0066] FIG. 6 illustrates a method for triggering a risk alert;
[0067] FIG. 7 illustrates a method for generating recommendations;
and
[0068] FIG. 8 illustrates an alternate method for generating
recommendations.
[0069] FIG. 9 illustrates a method for calibrating wearable
sensors;
[0070] FIGS. 10A-B show acceleration profiles generated by the
wearable sensors;
[0071] FIGS. 11A-B show rotation profiles generated by the wearable
sensors;
[0072] FIGS. 12A-B show acceleration profiles generated by the
wearable sensors; and
[0073] FIG. 13 shows a model for using the methods provided for
evaluating risks.
[0074] FIG. 14 is a flowchart illustrating a method for adjusting
insurance based on worker safety;
[0075] FIG. 15 is a flowchart illustrating a method for
incentivizing safe activities by workers;
[0076] FIG. 16 is a chart illustrating the setting of goals for
workers;
[0077] FIG. 17A is a flowchart illustrating a method for assigning
a device to a worker; and
[0078] FIG. 17B is a flowchart illustrating a method for assigning
a device to a worker.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0079] The description of illustrative embodiments according to
principles of the present invention is intended to be read in
connection with the accompanying drawings, which are to be
considered part of the entire written description. In the
description of embodiments of the invention disclosed herein, any
reference to direction or orientation is merely intended for
convenience of description and is not intended in any way to limit
the scope of the present invention. Relative terms such as "lower,"
"upper," "horizontal," "vertical," "above," "below," "up," "down,"
"top" and "bottom" as well as derivative thereof (e.g.,
"horizontally," "downwardly," "upwardly," etc.) should be construed
to refer to the orientation as then described or as shown in the
drawing under discussion. These relative terms are for convenience
of description only and do not require that the apparatus be
constructed or operated in a particular orientation unless
explicitly indicated as such. Terms such as "attached," "affixed,"
"connected," "coupled," "interconnected," and similar refer to a
relationship wherein structures are secured or attached to one
another either directly or indirectly through intervening
structures, as well as both movable or rigid attachments or
relationships, unless expressly described otherwise. Moreover, the
features and benefits of the invention are illustrated by reference
to the exemplified embodiments. Accordingly, the invention
expressly should not be limited to such exemplary embodiments
illustrating some possible non-limiting combination of features
that may exist alone or in other combinations of features; the
scope of the invention being defined by the claims appended
hereto.
[0080] This disclosure describes the best mode or modes of
practicing the invention as presently contemplated. This
description is not intended to be understood in a limiting sense,
but provides an example of the invention presented solely for
illustrative purposes by reference to the accompanying drawings to
advise one of ordinary skill in the art of the advantages and
construction of the invention. In the various views of the
drawings, like reference characters designate like or similar
parts.
[0081] FIG. 1 illustrates a typical environment in which the system
and method monitoring safety and productivity is deployed, FIG. 2A
is a schematic for a sensor implementation for use in the method,
FIGS. 2B-2D show one example of a sensor housing for the sensor of
FIG. 2A, and FIGS. 3A and 3B are flowcharts illustrating such
methods.
[0082] As shown in FIG. 1, workers, or other users of the systems
and methods described herein, may be deployed to various locations
within a warehouse 100 and may be required to perform a variety of
repetitive material handling tasks at each location. For example, a
first worker 110 may lift an object 120 from the floor to a shelf
130 in a first sector 135 within a warehouse 100, while a second
worker 140 may lift a separate object 150 off of a shelf 160,
rotate, and transfer it to a table 170 in a second sector 180 of
the warehouse 100. Additional activities may include a worker 172
unloading a truck 174 which may include walking up and down a ramp
176, jumping, or operating machinery, among other activities. It
will be understood throughout this disclosure that references to a
worker are references to users wearing the wearable devices 190
discussed herein.
[0083] Each of the workers 110, 140, 172 would typically be wearing
at least one sensor device, and in some embodiments, two sensor
devices, 190a, b for recording movement. Typically, where two
sensors are provided, the sensors used may be a wrist sensor device
190a, ideally located on the wrist or forearm of the dominant hand,
and a back sensor device 190b, ideally located approximately at the
height of the L1 and L2 vertebrae, but other sensor device types
may be implemented as well. The wrist sensor may incorporated into
a wrist device, such as a bracelet or a wristwatch, and the back
device may be incorporated into a chest strap, weight belt or back
brace, for example. Where only one sensor device 190 is provided,
it is typically applied to a worker 110, 140, 172 on or near the
worker's hip. However, the device 190 may be applied elsewhere and
the necessary dimensions and measurements may be extrapolated from
data recorded from the sensor device 190. The sensor device 190 may
take a variety of forms, and is referred to herein as any of a
sensor, a device, or a sensor device.
[0084] Accordingly, a single sensor device 190, referred to herein
as a wearable device, may be used to record movement. Such a sensor
may be mounted on a user's belt and may be used to predict or
estimate motion of the user's back and spine based on movements of
the user's hip. A system implementing such a wearable device may be
trained using a machine learning predictive model trained by
collecting data from sensors attached to a user's spine and
comparing that data to data collected at the user's hip. After
training such a predictive model, the single hip mounted wearable
device 190 may be used to evaluate movement of a worker's
spine.
[0085] Accordingly, in embodiments using a single wearable device
190, the wearable device is mounted at a workers hip, and the
measurements calculated include measurements of a user's back
inferred from movement of the user's hip detected by the wearable
device. Such movement of the user's hip may be detected by the
accelerometer 210, gyroscope 220, and altimeter 240, discussed
above.
[0086] In some embodiments, a single primary wearable device 190
may be used and it may communicate with various sensors or
transmitters on different parts of the user's body, as shown in
FIG. 4A, in an environment in which the user is working, as shown
in FIG. 4B, or on equipment the user is using. For example, a user
may have a primary wearable device 190 that interacts with safety
equipment worn by a user or with a humidity, temperature, or gas
sensor located in a factory.
[0087] A server 310 may further be included in the warehouse 100
for receiving data from the wrist sensor 190a and the back sensor
190b, or the single wearable device 190, depending on the
implementation, and storing records of activity performed by
workers 110, 140, 172. In some embodiments, signals generated and
transmitted by the wearable device 190 are received and processed
by the server 310. In some embodiments, results of the methods
discussed below are generated and retained by the wearable devices
190 and are used to provide immediate feedback to workers 110, 140,
172. In some embodiments, the results are transmitted to additional
terminal devices 195 to be accessed by a third party, such as a
manager, or by the workers themselves 110, 140, 172. While the
warehouse 100 shown includes a physical server 310, it will be
understood that the server may be a cloud server or may be coupled
to a cloud server to maintain a platform implementing the method
described.
[0088] In some embodiments, the results may be organized in a log
for retention by the system. Such a log, discussed in more detail
below, may be used by a manager to reschedule workers to tasks more
suited to them. It may also be used by employees or managers to
reorganize their time based on when they are most fatigued.
Further, the log may be used by insurance companies to modify
insurance rates and premiums based on employee risk profiles,
either for individual employees or for a company taken as a group,
as discussed in more detail below.
[0089] As shown in FIG. 2A, each wearable device 190 may include a
sensor array 200 including a 3-axis accelerometer 210, a 3-axis
gyroscope 220, a 3-axis magnetometer 230, a temperature sensor 240,
and an altitude sensor 250, such as a barometric pressure sensor.
Each sensor device 190 may further include a communication module
260 which may include multiple communication interfaces. For
example, each sensor device 190 may have a short range
communication interface 270 for enabling communications between a
first sensor device 190a and a second sensor device 190b worn by a
single user. The short range communication interface 270 may
further be used to receive signals from additional sensors or
devices on the user's body, such as safety equipment, or from
sensors or other transmitters in the user's immediate environment.
The wearable device 190 may further contain a longer range
communication interface 280 for connecting, for example, to a Wi-Fi
or cellular network. Each wearable device 190 may further include a
computation module 285, including a processor 290 and a memory
300.
[0090] Accordingly, each of the sensor devices 190a, b, may
communicate with each other (in embodiments where users wear
multiple sensor devices), or other local devices or sensors, using
the short range communication interface 270 and with the server 310
or a cloud network using the longer range communication interface
280. Signals generated by the sensor devices 190 may be processed
at the individual devices, may be combined with other data acquired
through the short range communication interface 270, or may be
transmitted to the server 310 or another centralized platform for
analysis.
[0091] The wearable device 190 may further incorporate a feedback
module 320 for providing feedback to the user. For example, the
feedback module 320 may include a motor for generating vibration
and providing haptic feedback, audible feedback in response to the
output of the method, and/or a display for visual feedback that can
show immediate as well as cumulative risk exposure. Further,
different levels or patterns of vibration in the context of haptic
feedback may be used to indicate different alerts to the user of
the device. The wearable devices 190 may further incorporate user
input means by which users can control the wearable device 190. For
example, the device may include modules for detecting and
interpreting voice or gesture based commands.
[0092] The wearable device 190 may have an additional module for
determining location by, for example, incorporating a GPS unit or
other geolocation components and processes. Alternatively, or in
addition to geolocation components, the wearable device 190 may
include a module for triangulating the location of workers based on
proximity to known landmarks, such as beacons.
[0093] The sensor devices may further include batteries for
providing power to the various modules therein. The sensor devices
may further incorporate LEDs, displays, or other methods for
delivering feedback to the workers 110, 140, 172 wearing the
sensors. For example, the device may utilize a display to display
the risk metrics, or a goal, rank or other relevant information
like battery and signal status. The display may be touch sensitive
in order to provide a user interface by way of the display. Other
information displayed can be error or warning messages when a
worker is detected to not be wearing the device correctly, or in a
variety of other scenarios discussed below in more detail. The
device can also show information like number of steps taken by a
worker, calories burned, active hours in the shift, current time
and the time to next break etc. This information can be shown when
a worker requests it, at regular intervals, or automatically when
one of the methods described below are used to identify a relevant
or hazardous situation.
[0094] In some embodiments, the user interface is replaced by, or
supplemented by, a separate portable device or an application for
use on a smartphone. In such a case, when an alert is triggered,
such alert may be transmitted to a user on his smartphone.
[0095] FIGS. 2B-D show a sensor packaging 2000 containing a clip
2010 for fixing the sensor device packaging 2000 to a user. The
sensor device 190, as discussed above, must be attached to the body
of a user, typically in a predetermined location or in one of
several potential predetermined locations. Once attached, the
relative motion between the user's body or clothing and the sensor
device 190, which would be noise in a signal generated by the
sensor, should be minimal. Accordingly, a robust fixation
mechanism, combined with appropriate calibration methods, described
below in more detail, are useful to reduce signal noise and
increase the accuracy of the various methods described.
[0096] FIG. 2B shows a sensor packaging 2000 having a clip
mechanism 2010 in an open position for fixing the sensor to a
user's clothing. The clip 2010 includes a lever 2020 which, when
rotated, converts its rotational motion into horizontal motion of a
clip, such as wire clip 2025, using a cam mechanism 2030. The cam
mechanism 2030 uses a cam surface 2040 and a pin 2050 interacting
with a track 2060 in order to implement horizontal motion in the
wire clip 2025. When the lever 2020 is fully lifted, as shown in
FIG. 2B, the wire clip 2025 is separated from a back surface 2070
of the sensor packaging 2000, providing a space for the user to
place the device over their belt or trouser rim. As shown in FIGS.
2C-D, once the sensor packaging 2000 is in position, the lever 2020
is rotated towards the sensor packaging 2000, which draws the wire
clip 2025 towards the back surface 2070 and then compresses the
user's belt or trousers by applying a normal force to the clothing,
minimizing the motion between the sensor packaging 2000 and a
user's clothing.
[0097] The normal force applied by the clip design can be varied by
modifying the parameters of the wire clip, which acts like a
spring. The length, design and material can all be modified to
obtain a required normal force. In addition, a high friction
material can be placed between the wire clip and back part of the
enclosure to increase the friction force between the device and the
clothing. For example a rubber coating can be placed on the wire
clip, or a rubber overmold may be placed on the back surface 2070
of the sensor packaging 2000. The wire clip can also be modified to
increase its range of motion by adding torsion springs or other
similar design methods.
[0098] The clip 2010 described may further comprise a switch
activated by the closure of the clip. For example, the clip 2010
may include a magnet incorporated into the lever 2020, such that a
magnetic field sensor, such as a reed switch, may be used to
determine when the sensor packaging 2000 has been applied to a
user's person. Accordingly, when the clip 2010 is closed on a
user's belt, the switch may indicate that the sensor 190 has been
positioned, and the device may initiate a calibration process, as
described in more detail below. Similarly, a capacitive surface
incorporated into the clip 2010 may be used to confirm that the
clip has been closed. Alternatively, a physical switch or button
may be included to indicate that the sensor packaging 2000 has been
properly positioned, and that the sensor 190 may now begin to
capture data, or a proximity sensor or a light sensor may be
incorporated to detect when the sensor packaging 2000 has been
placed on a user's body.
[0099] While the components of the two sensor devices 190a, b are
described identically in embodiments in which two sensor devices
are utilized, in some such embodiments, the sensors comprise
different components. For example, the wrist sensor 190a may not
include a longer range communication device 280 or a computation
module 280 and may instead immediately transmit signal data to the
back sensor 190b. The back sensor may then process the data and
transmit results to the server 310.
[0100] Other implementations are possible as well. For example, all
signals may be immediately transmitted from the wearable device
190, to the server 310 which in turn implements the methods
described. For the purposes of outlining the methods performed, the
methods will be described with respect to such a platform where
processing is handled centrally at a server 310. However, it will
be understood that the calculations and methods described may be
performed at any one of the wearable devices 190 described, or
across a combination of the wearable devices discussed. Further,
while the method described in reference to FIG. 3A discusses a
system using signals separately acquired from two sensor devices
190a, b, all required measurements may instead be acquired from a
single wearable device 190. In such an embodiment, a single signal
may be analyzed. Further, while some methods described detect
lifting activities, other physical activities may be detected as
well, as discussed in more detail below.
[0101] Accordingly, while workers perform material handling tasks
and other physical activities, including lifting objects 120, the
server receives both a signal from the wrist sensor 190a indicative
of the movement of that sensor over time (400) and a signal from
the back sensor 190b indicative of the movement of that sensor over
time (410). This may be received in the form of a data stream or a
transient signal, or it may be received in the form of chunks of
data received consecutively.
[0102] The server then evaluates (420) both signals to determine if
any portion of the signal represents the initiation of a lifting
activity. If a lifting activity is identified in the data, the
server then further evaluates (430) both signals to identify an end
point of the lifting activity. In some embodiments, this detection
of an initiation of a lifting activity and an end point of the
lifting activity is by way of a rules based approach directly using
variables obtained from the sensor data, or based on variables
detectable after only minimal signal processing. This rules based
approach may include, for example, measuring the back angle with
respect to the gravity plane and determining when it passes a
threshold. This type of threshold may be static or variable,
depending on other elements of the lift. Arm elevation angles may
further be used to detect lifts above the shoulder, for
example.
[0103] In some embodiments, the signals are used to identify only
an initiation of a lifting activity, but not an end point of the
lifting activity. In such an embodiment, a lifting activity may be
assigned a specified time limit, such that the lifting activity is
assumed to have concluded after a fixed amount of time has
passed.
[0104] In embodiments with only minimal signal processing prior to
identifying the initiation of a lift may comprise only filtering of
data to reduce noise and cancel any drift. Typically, filtering is
applied, such as a band pass filter, to ensure that more resource
intensive processing is applied only once a lifting activity is
detected within the more minimally processed data. For example,
drift in height sensor data and gyroscope data may be filtered to
reduce noise prior to identifying a lifting activity, and then the
filtered data may be utilized to detect the initiation of a lifting
task with a reduced number of false positives.
[0105] In some embodiments, the lifting activity will be single
lifting motion. In others embodiments, the lifting activity may
comprise the entirety of the moving of an object from a first
location to a second location. For example, the lifting activity
may comprise a first user 110 picking an object 120 up off the
floor and placing it on a shelf 130. Similarly, the lifting
activity may comprise a second user 140 picking up an object 150
off of a shelf, rotating, and placing the object on a table 170.
Alternatively, the lifting activity may be a simple lifting action
in preparation for a secondary action, such as walking with the
package.
[0106] Once a beginning and end point of a lifting activity is
identified, the portion of the signals from the wrist sensor and
back sensor between the initiation and end point of the lifting
activity are excerpted (440) from the signal to generate a first
segment of data corresponding to lift data from the wrist sensor
and a second segment of data corresponding to lift data from the
back sensor.
[0107] In some embodiments, data from the point of time of the
initiation of the lifting activity is taken and is processed
immediately upon detecting the initiation of a lifting activity. In
such a way, risk models depending only upon static posture at the
time of lifting may be implemented immediately and may provide
results before the completion of the lifting activity.
[0108] Optionally, the method may then evaluate (450) a portion of
the signals from the time period immediately before lift and
immediately following the lift. This may be used, for example, to
eliminate false positives prior to incorporating such results into
statistics being reported. For example, when a worker bends over to
lift something outside the scope of his task, such as a worker
bending down to lift a pen from the floor and place it in his
pocket. In such an example, the initial back bending angle and
lowering of the wrist, as measured by wrist height, would indicate
a lifting event. However, since the wrist would then align with hip
of the worker and the back of the worker would straighten, this
would not be considered a lifting event. Accordingly, the portion
of the signal immediately following the lift may then clarify that
the lift detected would constitute a false positive for the purpose
of statistics being gathered.
[0109] Once the portions of the signals corresponding to lifts are
excerpted, the method processes (460) the excerpted portions of the
signal to extract metrics required for risk models being evaluated.
The processing of the excerpted portions of the signal typically
incorporates methods designed to increase signal to noise ratio and
otherwise improve the quality of the data. This may include methods
such as low pass filtering, Kalman filters, Gaussian moving
averages etc., all of which combine to reduce the noise in the
signal and remove unwanted drift of signals, such as the barometric
pressure signals, from the sensor data. From the signal processing,
the method may compute several new variables such as back sagittal
angle or wrist elevation angle, as discussed further below.
[0110] In some embodiments, some amount of signal processing occurs
prior to step 420 so that a signature in the data corresponding to
a lifting activity may be more consistently identified. Such a
signature may be used to detect sequences associated with lifting
tasks, such as box grabbing, carrying, and dropping. In other
embodiments, the data is checked after the excerpts have been
processed to confirm that a lifting activity has indeed occurred.
For example, the data from the back sensor 190b may be monitored to
determine when a worker's back has bent over a certain amount. This
information may be coupled with data from the wrist sensor 190a to
increase accuracy. While the method is described with respect to a
lifting task, it will be understood that the task may be any number
of physical tasks, such as a known sequence of motions for
assembling a device or a specific task such as rebar assembly
within the construction industry.
[0111] Where the risk model being evaluated is the NIOSH lifting
equation risk model, the method extracts (470) from the data the
following values: [0112] H--a horizontal location of the object
being lifted relative to the body. This may be determined, for
example, by evaluating the horizontal difference in location
between the wrist sensor 190a and the back sensor 190b and
accounting for known offsets based on the angle of the back sensor
190b, and the known thickness of the trunk of the worker being
evaluated, as well as the offset from the workers wrist to his
hands. [0113] V--a vertical height of the object being lifted
relative to the floor. This may be determined, for example, using a
height sensor in the wrist sensor 190a, such as the barometric
pressure sensor 250 and further utilizing some of the signal
processing techniques discussed below. [0114] D--distance the
object is moved vertically. This may be determined by calculating
the difference in height at the time of initiation of the lift and
the conclusion of the lift. In cases where the lifting process
being evaluated includes both picking up and putting down the
object, this may be the difference between the highest and lowest
heights measured during the process. [0115] A--asymmetry angle is a
measure of how much the workers back is twisted during the process.
Where a worker 140 picks up a package 150 in a first location 160
and places it down in a second location 170, the amount of rotation
of the workers back is measured and evaluated. This may be
evaluated by extracting the data from the gyroscopic sensors in the
back sensor 190b and applying an offset based on the workers trunk
thickness. [0116] F--frequency of lifts performed, as computed from
lift detection algorithms. [0117] In some embodiments, duration of
lifting tasks may be implemented, as computed by the time lifting
activities have occurred and have been detected by lifting
algorithms. [0118] In some embodiments, an additional variable, C,
may be incorporated and evaluated to assess the quality of the grip
of a worker on a package.
[0119] The processing associated with these variables, as well as
those below may include computing a gravity vector from quaternion
data, which is obtained from the fusion of gyroscope and
accelerometer sensor data. In such embodiments, acceleration in
both horizontal plane and vertical direction may then be computed
using the gravity vector. Threshold based outliers may then be
removed from the data. Components of the back and wrist elevation
angles are then computed using components of the gravity
vectors.
[0120] Several required variables may be detected or confirmed by
way of machine learning algorithms. Similarly, the accuracy of lift
detection may be improved by way of machine learning algorithms.
Such algorithms may further be utilized to confirm the
identification of the activity detected, both in terms of improving
the detection of true positives and eliminating false positives.
More broadly, such algorithms may improve the precision and recall
of lift detection and variable evaluation. Statistical features
monitored by such machine learning algorithms may include:
[0121] Lagged cross-correlations between variables;
[0122] Dominant frequency components of the signal;
[0123] Movement intensity statistics;
[0124] Movement energy statistics;
[0125] Signal magnitude area; and
[0126] Window duration.
[0127] All of these statistics may be monitored over windows of
data which may be calculated based on elements of the signal, such
as those detected above in steps 420 and 430.
[0128] As discussed above, some variables may be detected directly
from the sensor data while others require further processing. Since
several variables are inferred, rather than detected directly, the
method may utilize confidence intervals in the estimates and may
report results, as discussed below, in the form of either
conservative or aggressive approaches, to calculate risk metrics.
Such approaches may be selected by a user operating a platform
implementing the methods.
[0129] The height of sensors is typically extracted from a
barometer, or other types of altimeters. Data from these sensors
tend to drift. Accordingly, the drift may be corrected by coupling
the sensor data with acceleration data in the gravity direction in
a Kalman filter. This may also be done by way of a low pass filter
for certain types of altimeters. Further, the height detector may
be calibrated by setting the height to a known value upon the
initiation of a lift. For example, the height of a back sensor may
be set to a fixed value at the beginning of each lift, regardless
of whether the worker is, for example, standing on a stool.
[0130] In some embodiments, some initial signal processing is
applied to the signals upon receipt so that the detection of the
beginning of a lifting activity may be made with more accuracy. The
initial signal processing may then be followed by more advanced
signal processing and machine learning algorithms for extracting
remaining variables from the data and for confirming that a lift
actually occurred during the time period excerpted from the
signal.
[0131] Besides travel distance for a specified value between the
beginning and conclusion of a lifting activity, each variable may
be independently evaluated with respect to the beginning of a
lifting activity detected and at a conclusion of a lifting activity
detected. For example, where a worker 140 moves a package 150 from
a shelf 160 to a table 170, if the worker faces the shelf while
doing so and twists his back 90 degrees to deposit the package 150
on the table 170, his angle will be 0 for the beginning of the
lifting activity and 90 for the end of the lifting activity.
[0132] Other ergonomic risk models may be implemented as well, and
may require extracting different values from the data. For example,
if implementing the risk model developed by Marras et al using his
Lumbar Motion Monitor, the data extracted from the signals may be:
[0133] Average twisting velocity of the torso during the lift
activity, computed in a way similar to the calculation of the
asymmetry angle discussed above, except using angular velocity.
[0134] Maximum moment on the lower back, which is computed by
multiplying the maximum horizontal distance between the load and
the worker's trunk and the weight of the object lifted. [0135]
Maximum sagittal flexion of the torso, which is determined by
extracting the offset bending angle of the lower back relative to a
vertical axis (usually gravity). [0136] Maximum lateral velocity of
the torso, which may be determined from the accelerometer gyroscope
in the back sensor. [0137] Frequency of lifts specified in lifts
per minute, which can be obtained from the frequency of lift
detection.
[0138] In some embodiments, the risk models specified may be used
to calculate a maximum recommended lifting weight based on a
workers lifting technique. This is done by using the variables
extracted from the signals in a risk model. For example, the NIOSH
risk model may be used to calculate a recommended weight limit.
Further, the model may be used to calculate a lifting index
identifying a risk associated with any particular lifting action or
task. Further, while the model is discussed in terms of lifts, such
a model or a similar model may be used to evaluate other activities
as well in order to determine a risk level for such activities. The
model used may then provide numerical results, or those results may
be classified in terms of low, medium, and high risk lifts.
Similarly, underlying values for variables may be implemented
directly in the models, or they may be mapped on to low, medium, or
high values.
[0139] Using the NIOSH risk model as an example, a recommended
weight limit for a single lift may be calculated by simply
determining each of the values discussed above, determining an
appropriate multiplier used in the model (typically determined from
a table associated with the model, or by calculating an appropriate
ratio) and multiplying the relevant multipliers. Accordingly, the
recommended weight limit may be determined from the equation
RWL=LC*HM*VM*DM*AM*FM where LC is a constant multiplier for the
formula, typically 51 lbs., and HM, VM, DM, AM, and FM are the
multipliers associated with the calculated values of H, V, D, A,
and F respectively. In some embodiments, an additional multiplier
may be used to incorporate the duration of lifting tasks. While the
NIOSH risk model is described, other risk models may be implemented
as well. Further, by dividing an actual weight lifted by the
recommended weight limit generated by the NIOSH model, a lifting
index may be generated providing an evaluation of the risk
associated with a specified lifting activity.
[0140] Further, data from individual workers may be correlated with
personal information for that worker. For example, a specific
worker's data may be correlated with that workers height, history
of back injuries or other medical issues, or other physical or
personal characteristics that may affect performance. Further,
measures of physical characteristics may be estimated, such as arm
length for workers, which can in turn be used to improve both the
ability to infer variable values from signal data and the ability
to use the variable values detected.
[0141] While NIOSH and Marras models are described, other risk
models may be utilized as well, such as Liberty Mutual.RTM. tables,
RUBA, RULA, and others. For example, the signals from the sensor
190 may be used to estimate the compression at a specified
vertebrae of the spine using a biomechanical model. That
compression may then be compared to a maximum limit, such as the
770 lbs. prescribed by OSHA, in order to classify a lift as
potentially high risk.
[0142] In this way, the selected risk model may be used to
determine a maximum recommended weight for any given lift (480).
Where the risk model used supports a determination for a single
point in time, the risk model may be implemented immediately
following the detection of an initiation of a lifting activity at
step 420. In such an embodiment, the information from the moment of
time detected is immediately extracted and processed.
[0143] Optionally, the method may extract (490) from the data an
approximation of the actual weight of a package lifted. Such an
approximation may be calculated by evaluating the angular velocity
or acceleration of the wrist sensor 190a. In some embodiments, this
may be compared (500) to the same metric for a known weight such
that the weight of an object may be inferred by comparing the
angular velocity of a specified lift by a worker to an angular
velocity associated with a lift for a known weight by the same
worker. The accuracy of this measurement may be further improved by
evaluating data related to the angle of the back sensor 190b and
similarly mapping it to known angles for known weights by the same
worker.
[0144] Similarly, metrics correlated with energy applied during a
lift may be implemented. Such metrics may draw signals from both
the back and wrist sensors and may be used to evaluate the weight
of an object lifted.
[0145] The various signals evaluated upon identifying a lifting
motion may then be used to detect acceleration in the vertical
direction in the world frame of reference. Accordingly, when a
worker begins a lifting process, the wrist based accelerometer may
immediately detect a jerking motion as the height sensor begins to
rise from its lowest position. The velocity of the rising motion
may then be used as a proxy for effort applied in lifting, which in
turn may be used as a proxy for determining the weight of an object
lifted. Such an approach may determine both the weight of the
object being lifted or, if the weight of the object is known, the
fatigue of the worker lifting the object. Either approach will
allow the system to determine an effective weight of the object
from the perspective of the worker. Including the fatigue of the
worker lifting the object in this way may further incorporate a
fatigue component in evaluating risk to the worker.
[0146] In such an embodiment, the approximate weight or effective
weight calculated is then compared (510) to the maximum recommended
weight (determined at 480) based on the model.
[0147] If the weight lifted is greater than the maximum recommended
weight, the sensor may provide feedback (520) to alert the worker
to the weight limit. Such feedback may be, for example, haptic or
audible feedback. In some embodiments, a combination of feedback
methods may be implemented, and the feedback may then be displayed
on a screen associated with the device or through an LED, and
haptic feedback may be implemented to prompt the user to view the
screen.
[0148] While the method is described in the context of a weight
limit in the context of lifts, additional risk metrics are
contemplated as well. Such metrics may be used to evaluate risk for
any activity, including the lifting of packages. Accordingly, the
risk metric generated provides a proxy for risk of an activity, or
set of activities, performed by a worker, and the system and method
may then compare that metric to a threshold to determine whether
the activity as executed is high risk.
[0149] While the method evaluates individual activities, the server
will continue to receive data from the sensor devices 190a, b.
Accordingly, the server may then store (530) a record of the first
lift in a memory associated with the server and return to step 400
and continue monitoring the sensor data to determine if the worker
is performing additional lifting activities. The server typically
continues to monitor the data for additional lifting motions over
the course of an evaluation period. In some embodiments, once
multiple lifts have occurred, the method calculates (540) a
frequency associated with the lifting motions identified and
incorporates (550) that value into the risk models in order to
monitor and evaluate risks associated with repetitive lifts. Such
frequency data may be used in the NIOSH model described above, for
example, to reduce the maximum recommended weight for a repeated
lifting activity based on repetitive stresses and associated
risks.
[0150] After the conclusion (560) of an evaluation period during
which lifting motions are evaluated, the risk models may be used to
evaluate (570) aggregate risk over the time period. In some
embodiments a worker's shift may be divided into blocks of time,
such as half hour blocks, for use as evaluation periods. In some
embodiments, the evaluation period is instead the entirety of the
worker's shift.
[0151] FIG. 3B is a plot illustrating high risk postures over time
for a worker, and FIG. 3C is a flowchart illustrating an
alternative method for monitoring safety. While the basic method
discussed may provide an alert, such as a vibration or device
display indicating a high risk physical activity or movement any
time such a movement was performed, such an approach may result in
a large number of alerts to a worker. Such a large number of alerts
may be ignored, or may irritate the worker. Accordingly, a separate
metric, described herein and mentioned briefly above, may be used
to evaluate accumulated risk over a period of time, and that metric
may be used to determine whether a worker should be alerted for
each individual high risk physical activity. This may take the form
of a running gauge over a time window.
[0152] Generally, in such an embodiment, if frequency and/or
magnitude of accumulated high risk motions is above a threshold,
the device would then alert a worker for every high risk motion
until the risk is reduced by either reduce the high risk motion,
such as by changing posture, or by using assist equipment or
resting, or by switching to a lower risk job function.
[0153] It is well known that a high frequency of high risk postures
can lead to an increase in musculoskeletal injuries. Frequency
would indicate a certain number of postures or high-risk postures
in a period of time. For example, FIG. 3B shows a plot of the
number of high-risk postures a worker performs over the course of a
day. Clearly from 7-9 am there is an increase in high-risk postures
due to some work related activity.
[0154] Accordingly, in some embodiments, the method may evaluate
aggregate or accumulated risk, in the form of a cumulative risk
metric, and risk associated with individual activities in
combination. Such a combination allows for the leveraging of risk
based insights. As shown in the flowchart, an entity implementing
the method, such as a server 310 or a wearable device 190, may
receive a signal generated from dynamic activity of the wearable
device over time (3000). The method may then evaluate the signal
(3010) and determine if a first physical activity was initiated
(3015) by identifying an initiation time for the physical activity
performed by the worker wearing the device 190. The method then
evaluates the signals further and calculates measurements of the
worker wearing the device 190 for the time period during the first
physical activity from the first signal segment for a time period
following the initiation time (3020).
[0155] The window over which the first physical activity is
evaluated is typically closed at the conclusion of the activity. At
that point, the signal segment corresponding to the first physical
activity may be excerpted (3030) and used for further evaluation or
storage. For example, it may be stored in a log of activity, as
discussed in more detail below.
[0156] The determination of a conclusion time (3025) for a
particular physical activity may be based on recognizing such a
conclusion in the signal. As discussed above with respect to FIG.
3A, the detection of an end point of a physical activity may be
based on a rules based approach, or it may be based on a specified
time limit. For example, if the physical activity is a lift, the
method may assume that the lift will take five seconds.
[0157] Accordingly, the calculation of the measurements of the
worker wearing the device is then used to generate a risk metric
(3040) associated with the first physical activity. As discussed
above, the activity risk metric is derived from a risk model based
on the measurements of the wearer during the corresponding physical
activity, and is indicative of a risk level for the corresponding
physical activity.
[0158] The risk metric derived (at 3040) may then be compared to an
activity risk threshold (3050) to determine if the first physical
activity was a high risk activity.
[0159] While the risk metric is derived and evaluated, the method
continues to evaluate additional physical activities identified in
the signal. This is by repeating the identification of an
initiation time by evaluating the signal (at 3010) and calculating
measurements of the worker wearing the device 190 for a time period
following the initiation time (at 3020).
[0160] The method then repeats the generation of an activity risk
metric (at 3040) for each identified physical activity from the
risk model based on measurements of the wearer during each physical
activity.
[0161] In addition to the activity risk metric generated for each
identified physical activity (at 3040), the method also generates,
or maintains, a cumulative risk metric (3060) indicative of a risk
level from multiple physical activities over time.
[0162] The method then determines if the cumulative risk metric
(generated at 3060) is above a cumulative risk threshold (3070) at
any given time. When a cumulative risk metric is above the
cumulative risk threshold, a worker may be considered to be at high
risk for injury if they perform additional high risk physical
activities. Accordingly, if a user performs a physical activity,
and the activity risk metric generated from that physical activity
(at 3040) is greater than the activity risk threshold, such that
the individual physical activity is considered to be a high risk
physical activity, the method may then determine if the cumulative
risk metric (at 3060) is above the cumulative risk threshold
(3070). The method then generates an alert (3080) to the worker, or
to a supervisor, only if the cumulative risk metric (at 3060) is
greater than the cumulative risk threshold (at 3070) and the
activity is considered to be high risk.
[0163] The cumulative risk metric may be for a sliding window of
time immediately prior to the calculation of the activity risk
metric (at 3040) for a particular physical activity. Accordingly,
prior to generating the alert (at 3080), which may be, for example,
haptic feedback, the method may determine if the user has been
performing high risk physical activities over the most recent
window. Such a window may be, for example, a half hour, or it may
be longer, such as daily or weekly. Alternatively, the window of
time may vary in length depending on the situation.
[0164] The cumulative risk metric may be, for example, a risk
frequency metric. Accordingly, the metric may be a measure of the
frequency with which the activity risk metric was above the
activity risk threshold during the sliding window of time for the
cumulative risk metric. The frequency threshold may be, for
example, a specified frequency goal or an average number of
high-risk postures over a full day. Accordingly, while the
flowchart in FIG. 3C shows the cumulative metric being maintained
(at 3060) based on the generated risk metric (at 3040), it may
instead draw from the comparison (at 3050) to consider the
frequency of the activity risk metric demonstrating a high risk.
Similarly, it may draw directly from the excerpted segment (at
3030) or the signal data (at 3020) to determine a cumulative metric
based on variables different from the activity risk metric.
[0165] Alternatively, the cumulative risk metric may be a measure
of rest periods between instances of the activity risk metric being
above the activity risk threshold. This may allow the cumulative
risk metric to consider cumulative rest time. Alternatively, the
cumulative risk metric may be a measure of the overall number of
physical activities performed during the sliding window of time,
such that the system may determine whether a worker is likely to be
fatigued. Being fatigued from a large number of physical activities
may result in a worker being more susceptible to the risk
associated with high risk individual physical activities.
[0166] In some embodiments, the cumulative risk threshold used may
change over the course of the day or across several days.
Accordingly, the threshold may be lowered, and a worker may be more
likely to receive an alert, during a time of day when the worker is
fatigued.
[0167] In some embodiments, the cumulative risk metric may be based
on kinematic variables including at least one of back bending angle
and cumulative trunk loading. For example, the cumulative risk
metric may be based on a time integration of the kinematic
variables over time. Accordingly, in such an embodiment, the metric
is based on an integration of the back bending angle over time and
an integration of the trunk loading window over time. The
cumulative risk metric may be based on variables different than
those on which the activity risk metric is based, or it may be
based on the same set of variables. Accordingly, the activity risk
metric may be based on a first physical model while the cumulative
risk metric may be based on a different physical model.
[0168] In this way, a worker can be alerted to high risk activities
during a time when they are above the threshold. The device may
alert the user, such as by haptic feedback, initially when the
cumulative risk metric crosses the cumulative risk threshold. This
would notify the worker when their unit has entered vibration mode.
If the cumulative risk metric returns below the cumulative risk
threshold, the device 190 would stop alerting the user for every
high risk physical activity.
[0169] As a result, workers would get more buzzes at the times of
day when their risky activity was at its highest (regardless of
whether or not it is at start of shift or end of shift), and would
ideally get fewer buzzes in situations like bathroom breaks, lunch
times, etc. It would also give the safest workers the opportunity
to not get buzzes at all during a given day even if they still do
5-10 high risk postures (HRP) here or there.
[0170] In some embodiments, additional cumulative risk metrics may
be maintained by the method or system described. Accordingly, a
worker may be monitored for cumulative risk over the window
discussed above, as well as a complete day and/or week. Other
cumulative variables may include cumulative trunk loading, position
and timing variables, and integrated kinematic variables, such as
daily integrated back sagittal angle or velocity.
[0171] In some embodiments, the cumulative risk metric may be used
to trigger a modification of a design of a job assigned to the
wearer. For example, if the cumulative risk metric is above the
cumulative risk threshold for a specified amount of time, the
design of the job for a specific worker may be modified to require
the wearer to utilize assist equipment.
[0172] As discussed above, in addition to lifts, a variety of other
physical activities and events are detectable. These other physical
activities or events may include actual risk indications, as well
as behaviors indicative of potential risk. For example, jerks, or
sudden motion put extra strain on a worker's body, and such jerks
may be identified by identifying spikes in the acceleration data.
The amplitude of the spikes along with their distribution over time
can be used to determine the intensity of and frequency of a jerk.
If such jerks are overly frequent, or overly aggressive, a safety
manager may be alerted to the activity.
[0173] Similarly, jumps can be detected and impact on the health of
knees can be inferred. For example, a distribution worker might
jump off of a truck with or without package in hands. The impact of
jump on the knees can be detected by looking at spikes in the
acceleration in the vertical direction and correlated with sudden
changes in detected height. The magnitude of the acceleration and
height when the jump occurs can give an indication of the intensity
of the impact. This can be reported, and feedback provided to
reduce the number of jumps that occur, or in order to reduce the
intensity of the jumps. These jumps can often lead to impact and
cumulative injuries on knees, ankles and hips.
[0174] In one embodiment the wearable device 190 could measure
running within a facility where running is not recommended, or
where surfaces could be conducive to slipping.
[0175] In another embodiment, the wearable device 190 could be used
to measure when someone is climbing up a ladder, and the amount of
time spent on each part of the ladder, or if a user is using an
elevator, by monitoring a change in the user's elevation. The rate
of change of height can help determine the action being
performed.
[0176] In another embodiment, slips which do not lead to falls can
also be detected, and considered as near misses. In addition, these
episodes can also be used to log information about incidents, such
as the time, and to which worker they happened to.
[0177] In another embodiment, the wearable device 190 can be used
to evaluate the driving of vehicles such as trucks and forklifts,
or the use of other industrial equipment. Based on the acceleration
and deceleration profiles, worker driving can be evaluated and
scored. The number of hard braking actions or extreme acceleration
can be tracked. Speed of the vehicle can be estimated and if it
surpasses a certain threshold, then action can be taken. In
addition, if the vehicle is involved in an accident or an impact,
it can also be detected and timestamped and data of the impact can
be preserved for future investigation.
[0178] Further, an activity log for a user over time can help
determine if they are exposed to gradual risks. The platform
described may detect a number and frequency of repetitions doing a
specific task, a number of steps taken, and an amount of motion,
vigor of motion, time spent seated or standing or moving. These
various factors can help determine the amount of fatigue and
necessary resting period to help recover. As discussed below, the
system may further incorporate environmental factors, such as
localized humidity, in order to refine a model for the amount of
fatigue a user might be experiencing. Such additional detail may be
from environmental sensors, or from additional sensors incorporated
into the wearable device 190 to measure, for example dehydration.
Alternatively additional sensors may be worn elsewhere on the body,
as discussed in relation to FIG. 4A below. The activity log may
also be used to evaluate user productivity or evaluate other
results of physical activities, such as accidents, as discussed in
more detail below.
[0179] For example, an activity log may be used to determine a
worker's schedule and shift scheduled activities to create optimal
rest/work intervals. The system may use worker data to determine
the effectiveness of their recovery periods, and thereby suggest
schedule changes. The system may integrate with necessary systems
at the facility to ensure that recovery schedules do not compromise
business demands. Further, the system may incorporate worker
preferences and company preferences in order to improve work/life
balance.
[0180] FIG. 3D provides one example of a method for developing and
leveraging a log of activity in the context of the methods and
systems discussed above. Accordingly, an entity implementing the
method, such as a server 310 or a wearable device 190, may receive
a signal generated from dynamic activity of the wearable device
over time (3100). The signal is indicative of physical
characteristics of the wearable device over time. The method may
then evaluate the signal (3110) and identify (3120) a first signal
segment corresponding to one of several expected categories of
physical activities. Such a category of physical activity may be,
for example, a lifting activity, a jumping activity, a climbing
activity, or others. The first signal segment is then correlated
(3130) with the corresponding category of physical activity, such
that the signal segment can be evaluated in the context of the
particular physical activity it corresponds to.
[0181] Once the first signal segment is known to correspond to a
particular category of physical activity, an activity risk metric
is generated (3140) for the first signal segment. This may be by
using any of the methods discussed above for generating an activity
risk metric. The method then records the signal segment, along with
the category of physical activity and the value of the activity
risk metric in a log (3150) associated with the particular worker
associated with the wearable device 190.
[0182] The method then repeats the evaluation process to identify a
plurality of signal segments, each corresponding to at least one of
the several expected categories of physical activity (at 3120).
Each signal segment is then correlated (at 3130) with the
corresponding category of physical activity, and is then used to
generate a corresponding activity risk metric.
[0183] Each individual signal segment is then recorded in the log
(at 3150) in order to generate a log of physical activity performed
by the worker associated with the wearable device 190, such that
the log defines the category of physical activity, the activity
risk metric, and the time for each signal segment. The log may
record additional data, such as the location of the physical
activity. In some embodiments, the log may include a complete
record of raw data recorded at the wearable device 190. In addition
to raw data, the log may further include any calculated angles or
metrics evaluated by the wearable device, as well as any kinematic
variables, temperature, air pressure, and height measurements and
changes at the time of the associated signal segment.
[0184] In addition to data received from the wearable device 190,
the log may further define environmental data, such as temperature,
air pressure, air quality, and the like retrieved from other
sensors or devices in the environment. For example, the location of
nearby forklifts may be incorporated, as well as sensor readouts
from nearby sensor beacons.
[0185] The correlation of the first signal segment, as well as each
subsequent correlation, with the corresponding category of physical
activity (at 3130) may be performed in several ways. In some
embodiments, the wearable device 190 monitors a location of the
device, using a geolocation module. Accordingly, the entity
implementing the method may receive such an indication of the
location of the device, and may then select the several expected
categories of physical activities based on physical activities
expected at the location of the wearable device at the time of the
associated signal segment. For example, the wearable device 190 may
indicate that the worker is in the warehouse adjacent a shelving
unit. This may indicate that the worker is either lifting objects
from the floor, or a cart, onto a shelf, or lowering objects from
the shelf to the floor or cart.
[0186] In some embodiments, a cumulative risk score can be
attributed to a geolocation along with a worker or job function. As
such, individual locations in the warehouse may be identified as
high risk and selected for reconfiguration by management.
[0187] Alternatively, in some embodiments, the signal segment may
be directly compared to an expected signal segment corresponding to
each of several potential categories of activity. The set of
potential categories may be a complete set of categories available
for analysis, or it may be a subset of potential categories
selected based on context. For example, the subset may be based on
a worker's location in a warehouse, as discussed above, or it may
be based on a set of activities that the particular worker is
scheduled to perform.
[0188] Alternatively, the correlation may be based on an expected
activity by a worker based on a schedule, or it may be based on an
action taken by the user to initiate a physical activity. For
example, the user may scan a package prior to lifting it.
[0189] The log may then be used to investigate workplace injuries.
A physical activity identified in the log may result in an injury
to a worker. Alternatively, in some embodiments, one or more
category of physical activities monitored in the method may be
forms of worker injuries. In such an embodiment, the method may
proceed by identifying, in the log, a physical activity
corresponding to a worker injury (3160), identifying a set of log
entries relevant to the worker injury (3170), such as the previous
one or several physical activities, and providing such relevant log
entry, including complete raw data recorded at the wearable device,
to an investigating entity (3180). Accordingly, if an employer is
investigating a workplace injury, they may be provided with a
segment of the log corresponding to a time period immediately
preceding the injury. Such data may be used to determine the root
cause of the incident, and to determine or exempt a user from
culpability.
[0190] Further, the platform monitors the worker's orientation at
any given time. Accordingly, in the event of a falls or stumble,
the device can determine the severity of the fall by measuring the
acceleration and angular velocity. Using the orientation, the
wearable device 190 can also determine if the worker has been in an
improper orientation for an extended period of time, and can
trigger an alert or an alarm to prompt appropriate action. Further,
the platform could measure falls happening on the same level or
falls happening on different levels. The combination of
acceleration, direction of gravity on the device, and the change in
height would allow the detection of a fall, and also the position
of the worker on the ground.
[0191] In some embodiments, the wearable device 190 may detect
individual motions, such that the device may detect unsafe
postures, such as high-risk bends, twists, and reaches, as well as
jumping off of vehicles or slips, trips, and falls. It can also
detect safe postures, such as squats. Using algorithms that can
distinguish different activities, the log can provide a mapping of
all activities of a workers day (or other period of time) in order
to map what percentage of the time is performed in safe postures,
unsafe postures, driving a forklift or other vehicle, taking a
break, walking, etc.
[0192] In some embodiments, the log may be used to characterize all
activities of a worker into safe activities, such as a squat for
lifting, pivoting instead of twisting, and the like, unsafe
activities, such as high risk bends, twisting, jumping off of
trucks, or reaching, and neutral activities, such as walking or
standing.
[0193] Accordingly, while the log is discussed in terms of
evaluating injuries, all activities performed by a worker in a day
may be analyzed in order to generate a complete risk profile in the
form of a risk score over time. Accordingly, a pattern may emerge
that demonstrates a high likelihood of an injury occurring soon, so
activities may be investigated before an injury or incident has
occurred. This would help understand and predict the propensity to
injury of the specific workforce.
[0194] As discussed in more detail elsewhere, the log may be used
by actuarial processes to price risk of injury, or other metrics,
into insurance policies. Accordingly, instead of blanket insurance
premiums for a company, workers may be categorized based on their
personal ergonomic risk profiles. Insurance policies could also be
priced dynamically based on worker performance. Similarly, the
volume of workers at the facility could impact the price of
insurance.
[0195] The logs generated for multiple users could be mapped to a
floor plan or map of the facility to see what activities occur at
each location, and to optimize the design of the location for the
activities that take place there. Risky areas can be mapped in
order to help prioritize which areas of a facility should be
redesigned. The log could further be used to evaluate the types of
activities performed by people who rarely get injured.
[0196] Further, using the log generated, an action center may be
provided for managers. The methods for the action center would
involve processing the worker data, finding certain cues that would
trigger an action, and display that action for managers or workers
to view.
[0197] Managers and safety personnel can then review prescribed
real-time invitations to action based on safety metrics for
individual workers, and predictions of future injuries. For
example, when a worker is engaged in a task and their rate of
high-risk postures is unusually high, the system can alert the
personnel team in order to make an informed decision. Alerts may
relate to increased energy expenditures, higher than average wear
time, risky biometrics, and other alerts. Such alerts can be sent
to managers and/or wearers of the devices.
[0198] The method may then predict and prevent injuries based on
historical injury data. In providing real-time decision information
data, the method uses historical data to predict the likelihood of
future injuries using the data from the device 190. When injuries
are predicted, or the probability of injury increases, the users or
managers will be alerted and courses of action may be
determined.
[0199] Groups of workers with similar risk profiles and movement
patterns can be addressed and trained by managers as a group. Such
groups may be identified in the form of common movement patterns
across several workers. For example, workers with more bends than
twists will be grouped together to discuss techniques and
strategies to mitigate those risky behaviors. Groups can be altered
based on flexible time periods to adapt to the facility's
needs.
[0200] Follow up coaching sessions may be automatically scheduled
in the system using various learning and memory based schedules
when integrating new movement patterns. Follow up coaching may be
scheduled based on real-time data. This provides flexibility to
increase the urgency of a coaching session for a worker if their
risk levels rise in a short period of time.
[0201] In addition to the identification of particular activities
based on extraction of orientation and acceleration data from the
sensor device 190, additional context may be provided for the data
by sensors or communication protocols used to calculate a user's
location within a facility or a distance from another object. For
example, in an indoor facility, beacons may be distributed, and
Wifi or Bluetooth signal strength or triangulation may be used to
estimate the position of the invented device inside the facility.
Similarly, in an outdoor environment, GPS can be used to estimate
location. In some embodiments, distance from a known object may be
estimated based on signal strength between the sensor device 190,
and a device or beacon at a known location relative to the
object.
[0202] Information about the worker's location may allow for
identifying additional worker activity as well as worker physical
activity with increased accuracy. For example, if the platform
detects that a worker has entered a region for which he is not
authorized, the device may trigger an alert to the worker or the
worker's supervisor.
[0203] Further, by locating multiple users and pieces of equipment,
the platform may detect when a worker comes within a threshold
distance of a moving piece of equipment, such as a heavy truck or
forklift, and may trigger an alert to the worker.
[0204] Further, the wearable device 190 may determine if a worker
has collided with a moving vehicle or is otherwise injured by
detecting any impact through the accelerometer, evaluating a
resting orientation of the worker, and/or using location
information to determine the distance to an object in order to
determine the cause of an impact. In those cases, the device may
vibrate to alert the worker and/or send an SOS to the server 310
and potentially alert emergency responders.
[0205] While the worker log is described in terms of detecting and
analyzing worker injuries, the log may be used in a variety of
different ways. As the wearable device 190 is able to detect and
identify certain activities performed by the worker, it can detect
unsafe postures, such as high risk bends, twists, and reaches. It
may also detect workers jumping off vehicles or even slips, trips,
and falls. The wearable device 190 may also detect safe postures,
such as squats. Using methods to distinguish different categories
of physical activity, as discussed above, allows for the creation
of a log which maps all activities of a worker's day (or of some
other defined period of time). The log may then be used to map what
percentage of time is spent in safe postures, and what percentage
of time is spent in unsafe postures. Other activity may be
identified as well, such as driving a forklift or other vehicle,
taking a break, walking, etc.
[0206] In addition to directly identifying injuries, the log may
then be used to generate a risk score over time which could then be
correlated to injuries. Such a risk score, similar to some
embodiments of the cumulative risk metric discussed above, may help
an employer understand and predict the likelihood of injury to
particular workers or the overall workforce. Such a log, as well as
the associated prediction of injury likelihood may
[0207] In some embodiments, the sensor device 190 may also be used
to time stamp when a user comes into work, takes a break, or ends
work by confirming the time period for which the user is within a
work zone. Accordingly, a device trigger can be used to determine
how many hours an employee has worked, and if they are allowed into
the premises. Triggers can be based on a variety of activities,
such as taking the device 190 out of its dock and returning it,
putting the device 190 on and off of a belt, starting to walk after
putting the device on, scanning an employee badge, or pressing a
button or taking other action on the device 190 once a worker puts
it on.
[0208] Accordingly, the device 190 measures some trigger event to
indicate that a worker is starting use and has started their shift.
The system may then integrate the device 190 into the facilities
time management system to determine the time periods that workers
are in attendance. In some embodiments, when the worker clocks in,
a display on the wearable device 190 may change color to indicate
attendance. The device may then similarly change color to indicate
a break or clocking out.
[0209] Further, while a user is at work, location can be used to
assist in determining an activity performed, as a user location can
be correlated with detected motion in order to label physical
activity based on time or location. Further, in determining the
particular activity performed, the user location can be used to
determine what activities would be expected to be performed in a
particular location.
[0210] The wearable device 190, together with the activity
detection methods described, may provide additional insight into
the productivity of workers and/or facility design.
[0211] Activity logs for individual workers may be reviewed to
evaluate, for example, the number of times a worker performs a
specified activity, and how long the activity takes, among other
data points. This information may then be mapped and optimized. For
example, mapping and breaking down the tasks performed by a
warehouse associate who is fulfilling an order will show them
picking up an order in a first location in warehouse, walking to a
specific shelf location to check inventory, spending three minutes
searching for the specific item, walking to a boxing and shipping
location, and leaving the box on a pallet for pick-up by a package
delivery company. This information may be recorded for several
employees, and the warehouse or process could be redesigned in
order to optimize the most common activities. This may be by
relocating goods or by reassigning tasks based on differences
between workers of the system.
[0212] In the context of project management and validation, the
systems and methods described may be used to confirm that workers
have performed required tasks. For example, on a construction site
the sensor device 190 could be used to determine what time an
electrician clocked in, which floor they spent most time on, an
amount of motion and activity measured, how long they spent working
in that location, and how that compares to what was planned for the
day. Invoices can be generated based on this data, as well as
progress reports for specific projects. Further, worker efficiency
may be evaluated based on the correlation between an actual log of
physical activity generated by the methods described herein using
the wearable device 4010 and a user schedule identifying expected
activities for the worker.
[0213] Productivity metrics may be developed and utilized based on
frequency of detection of certain activities. Such data may be
analyzed to search for relationships with other detected metrics.
For example, productivity can be correlated to changes in
dehydration as measured by sweat sensors, such as in the system
discussed below in reference to FIG. 4B, or to times of the day,
weather, or ambient or body temperature.
[0214] FIG. 4A shows a system in which the wearable device 190,
described generally as a wearable device 4010, may be implemented.
As shown, a worker 4000 may be provided with a wearable device
4010. The wearable device 4010 typically includes multiple
communication interfaces, as discussed above. This allows the
wearable device 4010 to connect to servers 310 either directly or
through a cloud computing interface 4020, in order to upload and
receive information, as well as additional sensors 4030, 4040, 4050
on the worker's body which may communicate with the wearable device
4010 and may be provided to keep the worker productive and safe.
These additional sensors 4030, 4040, 4050 may be applied directly
to the worker's body, as in the case of sensor 4040, or may be
integrated into safety equipment, such as sensor 4030, integrated
into a harness, and 4050, integrated into a kneepad.
[0215] The multiple communication interfaces may provide an ability
to communicate data in real time, including warnings and alerts,
through the wearable device 4010, using long range communication
methods like sub-GHz and cellular radio as well as short range
communication methods, such as WiFi and Bluetooth. In some
embodiments the wearable device 4010 may further provide a local
wired port, such that sensors may be connected using, for example,
a USB connection.
[0216] The sensors are typically small and use low power
communication like Bluetooth Low Energy to send warning messages,
and may be, for example, a gas detection sensor. Warning messages
may be received at the wearable device 4010 and communicated in
real time to the wearable device 4010 in order to trigger an alert,
where appropriate. Alternatively, the wearable device 4010 may
receive raw data from the gas detection sensor which may then be
evaluated at the wearable device 4010, and may trigger an alert
when an unacceptable level is detected.
[0217] The sensors may be integrated into safety equipment, such as
the harness 4060 containing sensor or transmitter 4030. In such an
embodiment, the wearable device 4010 may determine if a worker is
performing a task or is in a location in which such a harness 4060
is required. If so, the wearable device 4010 may require
confirmation that the harness 4060 is present and is securely
attached before authorizing a worker 4000 to perform an activity.
For example, in order to determine if such a harness 4060 is
required, the wearable device 4010 may detect the altitude of the
worker, and if the worker is at a high altitude and proper usage of
the harness 4060 is not detected, the wearable device 4010 may
alert the worker and ground personnel.
[0218] In some embodiments, the wearable device 4010 has onboard
memory and processing capability, such that the device may save and
analyze data to determine if real time feedback to the worker or to
an external entity is necessary and, if so, communicate this
feedback. Alternatively, or in addition to such on board
processing, some portion of the data analytics may be done on cloud
servers or local servers upon receipt of the data from the device,
as opposed to in real time.
[0219] Another potential communication method involves pairing the
wearable device 4010 with a gateway residing within the
communication range of the device. For example, using long range
400-1000 MHz signals to send the data from the device on a worker
to the gateway within one mile radius. The gateway can rely on
satellite communication at remote locations to send the data in
real time to the external entity. In some implementations, such as
on construction sites, a trailer with a communication hub may be
provided, and the communication hub may then connect to the
individual workers of a system implementing the methods
described.
[0220] In some embodiments, the additional sensors, such as the
wrist sensor 4040 may use the wearable device 4010 as a gateway for
relaying information to a server, or as a centralized processing
unit. Accordingly, the wrist sensor 4040 may detect information
about the worker, such as pulse rate, temperature, and hydration.
This information may be detected directly, or it may be derived,
such as deriving dehydration by evaluating skin conductance or
sweat detection. The wrist sensor 4040 may then send the data to
the wearable device 4010 for analysis, and the wearable device may
then provide recommendations, such as a recommendation to rest or
drink water. Further, as discussed above, the data recorded may be
correlated with other data collected in order to, for example,
evaluate the effect of dehydration on productivity.
[0221] Further, the invention can be employed to ensure compliance
with Personal Protective Equipment (PPE) policies, such as
confirming that a user is wearing gloves, hard hats, eye glasses,
as well as other safety equipment, such as harnesses, in
appropriate situations.
[0222] As an example of PPE compliance, eye protection glasses can
have a low power Bluetooth transmitter monitored by the wearable
device 4010. If a worker forgets their eyewear and walks out of
range of the transmitter contained therein, the wearable device
4010 can notify the worker.
[0223] In some embodiments, PPE may be tied to a location within a
warehouse. Accordingly, if a worker is detected to have entered a
location that requires hard hats or other equipment and is not
wearing such equipment, they may receive a message reminding them
or they may not be able to perform their tasks until the equipment
is detected.
[0224] Similarly, the wearable device 4010 may monitor activities
to determine if an activity being performed is authorized for a
particular worker 4000 or requires particular safety equipment. As
an example, a forklift may have an NFC, RFID, or Bluetooth
transmitter. When a worker approaches the forklift, the wearable
device 4010 may determine if the worker 4000 is authorized to drive
that forklift, and may confirm the proper use of safety equipment,
such as a harness. If a worker 4000 is not authorized to perform an
activity, the wearable device 4010 may trigger an alert to a
manager.
[0225] In some embodiments, the wearable device 4010 may function
as a key for equipment, such as the forklift, and may transmit an
activation signal for the equipment where appropriate. Accordingly,
the wearable device 4010 may transmit such a signal only if the
user is authorized to use the equipment, and if the user is using
all required safety equipment. In this way, the wearable device may
change the status of the equipment (on/off, repair mode,
maintenance requests, etc.). The wearable device 4010 may function
as a key to login and enable or disable access to equipment. The
equipment may be enabled only when the wearable device is active
and in the vicinity, or only when the wearable device has
permission to use the equipment.
[0226] In some embodiments, authorization to use the equipment may
be based on a risk metric, such as that discussed above.
Accordingly, a wearable device 4010 may only be granted access to
particular equipment when the device confirms that a user is under
a safety threshold, such as below a number of high risk postures
(HRPs) for a period of time. Similarly, equipment may be disabled
immediately if the worker's wearable device 4010 registers a HRP or
a slip or fall. The equipment may also be disabled, or a worker may
not be granted access, based on risk of use. For example, someone
with high levels of fatigue may not be able to use a particular
piece of equipment.
[0227] Alternatively, the wearable device 4010 may function as a
remote control for machinery with or without active user control.
For example, the movement of mobile carts, forklifts, robotic arms,
or other industrial equipment may be remotely controlled. Such
equipment may also be automatically deactivated when a worker is in
the equipment path or within a specified distance. This may be
determined based on geofencing technology. Equipment may be
activated or the status may be changed remotely, such as shutting
down an area and notifying nearby workers due to a safety
hazard.
[0228] As one form of remote control, the wearable device 4010 may
function as a beacon for self-navigating robots to follow the
worker around a warehouse or the like without active user control.
Similarly, the beacon may be used as a target for the robots, such
that they automatically deliver packages to the worker.
[0229] FIG. 4B shows an additional system in which the wearable
device 190 may be implemented. As shown, the worker 4000 may
similarly be provided with a wearable device 4010 which includes
multiple communication interfaces. As shown, short range
communication interfaces 4100, such as Bluetooth, WiFi, Zigbee, or
NFC may be provided to communicate with local devices, machines, or
sensors, while long range communication 4110, such as cellular
service, ISM band, or a longer range WiFi platform, may be provided
in order to allow for communication with a cloud computing platform
4120 or a server 310.
[0230] In such a system, the short range communication 4100 allows
the wearable device 4010 to communicate with the local environment.
For example, a machine 4120 on which the user is working may be
equipped with sensors to assist in diagnostics. Accordingly, the
status of such machines may be provided to the worker 4000 when the
worker approaches that particular machine.
[0231] Similarly, the machine 4120 may communicate with the
wearable device 4010 in order to assist the various methods
described above to identify a particular physical activity in which
the worker 4000 is engaged, or in order to allow the wearable
device 4010 to determine if any safety equipment should be required
for the user.
[0232] As another example, in such a system, multiple environmental
sensors may be distributed throughout a work environment in order
to monitor various environmental data, such as local humidity or
temperature, or to detect danger, such as elevated gas levels.
Accordingly, the wearable device 4010 may retrieve data from a
local environmental sensor when the user is within range of the
individual environmental sensors.
[0233] Such environmental sensors may be provided with transmitters
with minimal communication range in order, for example, to preserve
battery life or prevent interference. However, in some embodiments,
the information from those environmental sensors may require
centralized processing. Accordingly, when the wearable device 4010
is within range of such an environmental sensor and retrieves data
from it using the short range communication interface 4100, it may
then relay that data to the server 310 using the long range
communication interface 4110.
[0234] Accordingly, in such a system, the server 310 may be
configured to record the environmental data in a database with the
identification of the corresponding sensor from which the data was
acquired. By maintaining the data from multiple environmental
sensors acquired at various times by multiple workers, the system
may achieve high resolution data by receiving, for example,
humidity data from humidity sensors distributed across a work
environment when any of several workers 4000 of the system
described walks past such a sensor. This data may then be analyzed
and monitored for changes. If, for example, a gas level or pressure
level spikes, or data otherwise differs drastically from an
expected data point, an alert may distributed to all workers.
Similarly, information from sensors in different locations may be
monitored, and if adjacent environmental sensors show different
environmental data, the sensors may be checked for either localized
problems or sensor errors.
[0235] FIG. 4C shows an additional system in which the wearable
device 190 may be implemented. As shown, the worker 4000 may
similarly be provided with a wearable device 4010 which includes
multiple communication interfaces, as in the system shown in FIG.
4B. However, in such an implementation, the short range
communication interface 4100 provided may be used by a first worker
4000a to communicate with additional workers 4000b-e in order to
bypass long range communication, or to pass a signal to different
workers 4000c within range of long range communication 4110 when
the first worker 4000a is out of such range.
[0236] Such a system may be implemented in order to increase the
overall range of the system, such that when wearable device 4010a
of a first worker 4000a is out of range of the cloud computing
platform and therefore cannot relay information to a server 310, it
may instead relay information to a wearable device 4010c of a
secondary worker 4000c which can in turn relay the data to the
cloud computing platform 4020. Accordingly, while the system
described in reference to FIG. 4B discusses the relaying of data
using the long range communication interface 4110 to transmit the
data to a server 310, the system could instead relay to other
workers 4000b.
[0237] The system may further be implemented in order to use mesh
networking protocols, such as Zigbee, to have wearable devices
4010a-e communicate directly with each other. For example, the
wearable device 4010a of the first worker 4000a may detect some
risk, such as elevated gas levels. The wearable device 4010a may
then trigger a warning in nearby wearable devices 4010b-e.
[0238] A system in which user wearable devices 4010a-e may
communicate directly with each other may also support direct
messaging between workers.
[0239] A mesh network may be implemented using beacons and
workplace equipment, as discussed herein. Communications may
leverage zigbee, Bluetooth Low Energy, Bluetooth 5, or WiFi direct,
among other communication protocols. Such mesh networks can provide
bidirectional information to the wearable device 4010. For example,
it may alert workers in case of an emergency, it can interact with
facility systems, and workers can send alerts to other workers, as
well as to the facility itself. The mesh network may also serve as
a redundant form of communication to insure delivery of messages
and link facility equipment to communicate safety issues.
[0240] Wearable M2M communications can be used to trigger events or
control equipment, as discussed elsewhere herein. A wearable device
4010 can be used to clock in and out of a facility, and can alert a
worker when certain equipment provides information. Equipment can
know who is near or operating it. Accordingly, the mesh network can
authorize permissions for specific workers, and the equipment can
record and transmit user information, such as application rates or
usage duration or frequency. The wearable device 4010 can also act
as an electronic lock out/tag out system.
[0241] FIG. 5 illustrates a method for enforcing safety rules
implemented in the systems shown in FIGS. 4A-C. As shown, the
method first receives (5000) a first signal from a worker's
wearable device 4010 indicative of physical characteristics of that
wearable device over time. In some embodiments, the method may be
further provided (5010) with additional information specific to the
worker, such as permitted or scheduled activities for that user, or
information related to a location. In such embodiments, the method
may then identify (5020) based on the additional information a set
of physical activities that could be expected to occur either by
the particular worker or at the worker's location. For example, if
the worker is at a high altitude, or at a loading dock, specific
physical activities may be expected. Similarly, the method may
receive information related to objects or industrial equipment
present at the location. For example, if a worker is determined to
be adjacent a forklift, that worker could be expected to drive the
forklift.
[0242] The method then identifies (5030) in the signal a signal
segment corresponding to one of several expected physical
activities and compares (5040) that identified signal segment to
expected signal segments for each of the expected physical
activities. Once a particular physical activity is identified, the
method may identify (5050) specific safety equipment or
certifications as required for the physical activity and may
confirm (5060) that the item of safety equipment or certification
is present. This may be implemented, for example, in the system
shown in FIG. 4A by providing the safety equipment with a
transmitter so that it can communicate with the wearable device
4010. In such an embodiment, the wearable device may confirm the
presence of a signal from the safety equipment.
[0243] If the presence of the safety equipment cannot be confirmed,
the method may trigger an alert (5070) either to the worker or to a
supervisor warning that the activity should not proceed until the
safety equipment is used. For example, if a worker is at altitude,
but cannot be confirmed to be wearing a harness, an alert may be
triggered by the method. In some embodiments, the method may
prevent further activity by the worker. For example, if the worker
is operating equipment without proper safety equipment, such as a
worker using or preparing to use a forklift without proper
harnessing, the wearable device may transmit a signal to the
forklift to turn off, or may prevent the forklift from turning
on.
[0244] A signal from the safety equipment may, in addition to
indicating the presence of the safety equipment, indicate proper
implementation of the equipment. For example, a user may be
notified if a harness is improperly attached, or if a hard hat is
present but not being worn.
[0245] In the system shown in FIG. 4B, for example, the wearable
device 4010 may be in communication with a piece of industrial
equipment that requires activation. In such an embodiment, the
wearable device 4010 may contain an activation key to be
transmitted to the industrial equipment. In such a system, the
activation key may be transmitted only if an item of safety
equipment required for the operation of the industrial equipment is
confirmed to be present. In such an embodiment, the activation key
may be transmitted to the industrial equipment upon receipt of a
confirmation signal from the safety equipment.
[0246] Further, the method may limit the types of activity it
searches for based on proximity to industrial equipment. For
example, when a worker 4000 uses a forklift, the method may monitor
acceleration and deceleration profiles to determine risk associated
with the user's driving. Hard braking or extreme acceleration may
be tracked, and the speed of the vehicle may be estimated. Further,
any impact can be evaluated.
[0247] FIG. 6 illustrates a method for triggering a risk alert in
the context of the system of FIG. 4B. As shown, a worker 4000 may
be provided with a wearable device 4010. Using, for example,
portions of the method of FIG. 5, the system may first identify a
physical activity (6010) performed by a worker 4000 of the system
based on a first signal retrieved from the wearable device 4010.
The method may separately receive (6020) a signal from an
environmental sensor independent of the wearable device 4010. Such
a signal may provide environmental data, such as a humidity level,
gas level, or temperature level for the worker's location. The
method may then calculate measurements (6030) of the worker 4000
from the first signal for a time period corresponding to a physical
activity being evaluated and may then calculate a risk metric
(6040) from a risk model incorporating the environmental data
received from the environmental sensor, compare (6050) the risk
metric calculated to a threshold and trigger (6060) an alert of the
risk metric indicates a risk level above a safety threshold.
[0248] Incorporating the environmental data into the risk metric
may increase the calculated risk in certain scenarios. For example,
high humidity may increase worker fatigue, resulting in an increase
of risk level associated with a particular activity.
[0249] Environmental data may also provide information about the
location and status of equipment. For example, a worker may be
provided with information about the last known worker of specific
equipment, or a date of most recent maintenance on the equipment.
Workers may be provided with alerts if moving pieces of equipment
are getting too close and should be avoided. Similarly, the system
can also track workers of specific machinery, to monitor chain of
custody if equipment breaks or to find a most common worker for
equipment.
[0250] This type of equipment specific data, or metrics related to
equipment data can be used to compare the risk metrics, discussed
above, with worker activities. This can be used to determine a safe
or high risk posture rate to calculate productivity or safety
metrics. For example, if equipment indicates that a worker has
lifted or placed 1000 boxes, the system may indicate what
percentage of such actions were safe and what percentage involved
HRPs.
[0251] FIG. 7 illustrates a method for generating recommendations
based on the data and risk model outputs received in the method of
FIG. 3. The server first receives (600) values for the risk metric
calculated in such a method with respect to individual physical
activities for multiple workers.
[0252] The server further receives (610) scheduling data for
individual workers including information related to the location
within a warehouse that each worker is assigned to. This scheduling
data typically contains, for each worker, a location at which they
would be working at any given time. The server then correlates
(620) the scheduling data with the risk metric for individual lifts
in order to determine a location for the individual lifting
activities associated with the risk metrics calculated.
[0253] The server then identifies (630) specific physical
locations, in the form of warehouse sector numbers, for example, at
which the risk metric illustrates a high risk across multiple
workers. The method may then recommend (640) location based changes
based on the data underlying the risk metric showing high risk. For
example, where the risk metric shows that multiple employees are at
increased risk because an object must be lifted from a high
location, the platform may recommend lowering a shelf on which
objects rest or adding a stool for workers to stand on while
lifting. Similarly, if workers consistently rotate their backs
excessively while performing a task at a specific location in a
warehouse, the platform may recommend adding a conveyor to that
sector of the warehouse.
[0254] Similarly, the server may identify specific tasks rather
than physical locations, that result in increased risks for
workers. For example, if the first worker 110 and the second worker
140 both generate increased values of the risk metric when their
schedules indicate that they were each performing a specific task.
Accordingly, if multiple workers consistently demonstrate increased
risk when, for example, unloading trailers, that task may be
highlighted as a high risk task, and the platform may recommend a
change in the methodology for performing that particular task.
[0255] A platform incorporating the method may present this data in
a number of ways. For example, it may provide a heat map
illustrating metric values.
[0256] Rather than incorporating worker schedules, in some
embodiments, the sensors 190 may have an additional module for
determining worker location by, for example, incorporating a GPS
unit or other geolocation components and processes. Alternatively,
the sensors may triangulate the location of workers based on
proximity to known landmarks, such as beacons.
[0257] The server may further identify (650) specific workers with
higher average risk metrics than others in specific areas. In such
a scenario, the method may recommend (660) changes specific to that
worker, such as corrections to the worker's posture, or it may
recommend (670) utilizing that worker in a different location in
the warehouse where they would not be placed at risk. For example,
where a specific worker is shorter than others and therefore shows
an increased risk in a specific location, the platform may
recommend reassigning that worker to a different region.
[0258] Accordingly, if a particular job is categorized as high risk
for a particular worker, based on wearable device data and previous
history data, the amount of time the worker spends on that task can
be optimized. Similarly, if a worker is engaged in a high risk
activity, the data can be analyzed in real time to determine if a
worker should change takes based on the rate of high risk postures
and energy expenditures.
[0259] In some embodiments, workers can receive individualized
messages at their own devices 4010. This may be based on worker
biomechanical data, such as specific advice to focus on reducing
twists, for example. Messages may further advise taking breaks as a
response to fatigue metrics. Messages can further relate to worker
task assignments related to certain stations, machines, or
locations. For example, "station number XY12" would allow a worker
to confirm which station they are assigned to. Similarly, a machine
or task may be assigned to a worker. The worker may then push a
button or tap the wearable device to indicate task completion.
[0260] Additional messaging features are considered as well. For
example, workers may be grouped based on a region within a building
or work environment, and messages may be sent to a group and
displayed on each worker's wearable device 4010. This could notify
workers of region specific information or warnings, or may provide
instruction upon entering or leaving the region. The messages could
similarly alert workers to emergency procedures, such as triggering
a building evacuation.
[0261] The device may display additional messages on the screen as
well, such as messages related to safety and productivity. These
may include reminders to stay hydrated, for example. Messages may
relate to locations, and may be triggered when the wearable device
passes a specific location. For example, as the worker passes by a
prohibited area, a message may indicate the same to the worker.
[0262] Further messaging may be provided based on conditional needs
of an organization. For example, a group of workers may be summoned
to the manager's office using the messaging features. Similarly,
messaging can be used to notify workers of dynamic operational
needs of an organization, such as for increased output, schedule
changes, or logistical changes.
[0263] Social motivation and competition may be incorporated into a
work environment using the methods described. Accordingly, the
wearable device 190 can be used to encourage motivation towards the
goal of reduced injury risk and improved productivity in several
embodiments. In some embodiments, feedback may be provided to
individual workers relating their performance to the performance of
others. This may be in the form of a rank on a leaderboard, for
example.
[0264] In such an embodiment, a worker wearing the device, can
access, through the device or through a related platform, an
employee ranking or leaderboard which shows the rank of the worker
for a specific metric compared to their peers. For example, a
ranking of workers may be provided based on the number of high risk
lifts they have performed over a given time period. By seeing their
rank, a worker may be motivated to improve their performance,
especially if combined with incentives, such as a gift card, points
etc.
[0265] Alternatively, a worker may be provided with a daily target
for a specific metric, which can then be shown on the screen of the
device. When the worker achieves the goal, the device may provide a
notification to the worker or management. For example, a target for
a productivity metric, such as number of lifts, or a goal for a
safety metric, such as the number of lifts performed with good
biomechanical posture may be created within the systems described.
Workers may be alerted when they achieve daily goals or are ranked
well relative to coworkers. Information displayed to individual
workers would be catered to their individual needs based on their
biomechanics data.
[0266] The platform may further advise on shift changes. In this
embodiment, workers who are at increased risk of injury after a
certain number of hours of their shift because of fatigue, or other
reasons, can be shifted to another task that uses alternate muscles
in order to reduce their risk of fatigue induced injuries. In
addition, the unloading or loading of a trailer, or other high
intensity tasks, can be scheduled to coincide with times of the
shift where workers at least fatigued.
[0267] FIG. 8 illustrates an alternate method for generating
recommendations. As shown in the figure, the server monitors (700)
the values of the risk metric determined in the method of FIG. 3A
across multiple physical activities for a specific worker. If a
specific one of the physical activities performed by the worker
demonstrates increased risk as measured by the risk metric, the
platform evaluates (710) the data underlying the specific physical
activity being evaluated. The platform then compares (720) each of
the underlying metrics to the corresponding metrics determined for
earlier corresponding physical activities performed by the same
worker.
[0268] If the underlying metrics differ in a specific identifiable
way from earlier lifts, the platform determines (730) if the
underlying metrics is correctable by the worker, and if so,
provides a recommendation (740) to address the change. For example,
where the platform notes that the horizontal distance between the
workers back and wrist has changed, or the worker's back angle has
shifted, it may recommend correcting the worker's posture. The
platform may determine that the value has changed by checking each
value underlying the metric for each physical activity against the
average value of the corresponding measurement. If there is a
significant difference, such as if the value differs by more than a
threshold percentage, the platform may recommend a corresponding
change.
[0269] Further, in some embodiments, if the risk as described by
the model is above a threshold, the individual components of the
risk models may be analyzed to determine the cause of the
underlying risk, and to present recommendations for addressing the
high risk level. For example, if the risk metric provides an
increased value and the platform determines that the frequency
multiplier is abnormally high, recommendations may be provided
based on reducing the frequency rates of a specified activity, such
as lifts or having more workers perform the job so as to reduce the
load on each individual worker.
[0270] This recommendation may be provided to a worker as soon as
detected by the platform by providing feedback corresponding to the
aspect of the worker's posture that should be addressed. For
example, where the distance between wrist and back has changed,
haptic feedback may be applied to the worker's wrist, while if the
back angle has changed, such feedback may be applied to the
worker's back.
[0271] Additional recommendations may be generated by the platform.
For example, depending on the values for the variables underlying
the risk metric, the platform may recommend bringing a load closer
to the worker by removing any barriers or obstacles between the
worker and the load, avoiding lifts beginning near the floor,
avoiding lifts over shoulder height, reducing the vertical distance
between the origin and the destination of a load, reducing a
lifting frequency, or allowing for longer recovery periods between
lifts. Further, the platform may recommend improving posture by
straightening the worker's back and lifting with his legs or
turning feet and stepping to move loads rather than having a worker
twist his back.
[0272] In addition to recommendations, a platform implementing the
method may generate actionable visualizations by summarizing
metrics recorded over the course of an evaluation period, or over
an extended period of time, by providing charts indicating high
risk times of days, weeks, or months, so that specific risks may be
identified and addressed. The platform may further identify, for
example, a percentage of high risk lifts or total number of high
risk lifts performed in a specified period of time.
[0273] Such an evaluation may be done in real-time by providing
such feedback during a work shift. Alternatively, or in addition,
the platform may provide (750) an end of day evaluation. Such an
evaluation may, for example, demonstrate worsening posture over the
course of the day indicating fatigue. In such a scenario, the
platform may provide a recommendation (760) such as a scheduling
change or a reorganization of tasks. For example, the platform may
recommend lifting heavier objects earlier in a shift.
[0274] While the method is described with respect to a risk metric,
the method may further be used to monitor productivity across tasks
for individual workers. This may be by monitoring, for example,
frequency of lifts, or productivity over the course of a shift. For
both the methods illustrated in FIGS. 7 and 8, where
recommendations are made, the results of those recommendations may
be monitored based on the productivity metric as well as the risk
metric in order to evaluate whether the recommended change was
effective. Accordingly, where a piece of equipment was recommended
and implemented in a specific location, the platform may monitor
future activity in that location to determine if injury risk has in
fact decreased and/or to determine if productivity has in fact
increased in that location. This information can be incorporated
into future modeling of that particular change.
[0275] Metrics relating to productivity of individual workers may
be further developed, and productivity based metrics may be
utilized to evaluate relationships between fatigue and
productivity. Accordingly, the platform may provide estimates of
return on investment for individual pieces of equipment that may
both reduce injury risk and increase productivity. In some cases, a
reduction in injury risk may lower productivity, while a
requirement for a worker increasing productivity may increase the
risk for that particular worker. The platform described may
determine an appropriate balance of increasing a worker's
productivity while maintaining the risk metric below a specified
threshold.
[0276] In some embodiments, fatigue of workers may be evaluated by
estimating energy associated with motion of the worker. Fatigue
affects risk and is typically incorporated into measurements in the
form of lift rate, and in generating an effective weight lifted, as
discussed above with respect to step 490. Fatigue may be further
evaluated by monitoring average acceleration rates of the wrist and
back of the worker over time, including during non-lifting
activities, such as inventory checking or manufacturing processes.
By detecting reductions in acceleration rates over time, such a
method may then identify fatigue and determine potential and
kinetic energies expected by a workers body.
[0277] The platform described may provide immediate feedback to
workers themselves, or it may provide feedback directly to
managers, either through on screen notifications at their
workstations or through text messages to immediately notify a
manager to an increase risk level for an employee. Similarly, the
platform may provide rankings for individual workers, or may alert
the manager when the workplace as a whole has generated an
increased risk profile.
[0278] FIG. 9 illustrates a method for calibrating wearable sensors
190. Such a method may be implemented using the sensor packaging
2000 shown in FIGS. 2B-2D in order to properly calibrate the
sensors 190 prior to beginning the detection of particular
activities.
[0279] The method initially confirms (7000) that an actual physical
posture or movement of a worker wearing the wearable device 4010
corresponds to a known physical posture or movement, captures an
initial state of all sensors, and begins to receive (7010), at a
processor, a first signal from a wearable device 4010, the signal
indicative of physical characteristics of the wearable device 4010
over time. For example, the signal may reflect orientation, height,
or acceleration information indicative of the location and movement
of the wearable device 4010 over time.
[0280] The actual physical posture may be, for example, a
standardized standing or sitting position. The confirmation of such
posture may be by monitoring a clip 2010 on the wearable device
4010 and proceeding with the method upon the closure of the clip.
The closure of the clip 2010 may be detected by a switch integrated
into the clip, such as a magnetic field sensor or reed switch. In
some embodiments, a worker may be instructed to assume a particular
posture, such as standing up straight, and may then confirm that
they have assumed the posture by, for example, gesturing or pushing
a button confirming the posture assumed posture. In some
embodiments, a worker may tap the wearable device 4010, resulting
in a spike of acceleration data from the accelerometer 210, in
order to indicate that the posture has been assumed. In some
embodiments, such confirmation may be a voice command, a gesture, a
physical switch, or a proximity sensor.
[0281] Alternatively, the method may require the worker to assume
one of several known postures and instruct a worker to either sit
straight up or stand straight, and the wearable device 4010 may
detect which position has been selected and calibrate
accordingly.
[0282] The method then initiates (7020) a calibration sequence. The
calibration sequence correlates the first signal received from the
wearable device 4010 with the known physical posture of the device
at that time. Accordingly, the calibration sequence includes
recording offsets (7030) for the first signal in a memory, the
offsets accounting for any difference between an expected first
signal and the physical characteristics actually measured in the
first signal.
[0283] The offsets recorded may include offsets to be applied to
raw data from a 3-axis accelerometer 210, gyroscope 220,
magnetometer, or altimeter, or to a fusion of data, such as
quaternion data.
[0284] Once the offsets are recorded, they are incorporated (7040)
into an adjusted first signal, and the adjusted first signal is
then used to implement the various methods described elsewhere in
this disclosure. Accordingly, once the first signal is adjusted,
the method identifies, (7050) in the adjusted first signal, a
signal segment corresponding to a physical activity, and calculates
(7060) a risk metric from a risk model based on the signal segment
corresponding to the physical activity, the risk metric being
indicative of high risk physical activity.
[0285] In some embodiments, the method continues to monitor (7070)
the adjusted first signal and identifies (7080) a signal segment
corresponding to a known category of calibration error. For
example, if the wearable device 4010 is knocked and is rotated with
respect to the worker's belt line or slides along the worker's
belt, the adjusted first signal may provide data indicating a
dangerous motion, when the data really indicates a calibration
error based on the new positioning of the wearable device. As one
example, FIG. 10A shows an acceleration profile corresponding to a
user of the wearable device 4010 walking. FIG. 10B shows that
acceleration profile modified by a known category of calibration
error, where, for example, the wearable device 4010 is knocked out
of alignment while the user is walking.
[0286] Accordingly, if such a calibration error is detected, the
method may identify (7090) the current actual posture or motion of
the user by incorporating the calibration error into its evaluation
and reinitiate (at 7020) the calibration sequence. In some
embodiments, the calibration sequence is reinitiated at regular
intervals, regardless of whether a known category of calibration
error is detected, in order to maintain proper calibration.
[0287] The identification of the current actual posture or motion
of the worker (7090) may be, for example, by monitoring the first
signal for common known acceleration profiles, such as a worker
walking profile shown in FIG. 10A. The method may then implement
the calibration sequence while the worker is walking by, for
example, averaging the movement of the user to determine the
appropriate offsets for the device. In other embodiments, the
method may observe the worker walking to confirm that the segment
of the first signal is, indeed, indicative of a calibration error
and may then initiate (at 7020) the calibration sequence when the
worker stops walking, assuming the worker remains upright.
[0288] Alternatively, once the system is properly calibrated, the
method may monitor a moving average of common known acceleration
profiles. In such a case, if the moving average moves dramatically,
such as that shown in FIG. 10B, the moving average algorithm may
either modify the offsets or compensate the algorithms accordingly.
Various statistics other than a moving average may be used as
well.
[0289] In some embodiments, the calibration method may further
determine a wearing position or device location of the wearable
device 4010 relative to the worker. To do so, the method may
monitor (7090) common known acceleration profiles, such as the
profile of a user walking shown in FIG. 8A, and may excerpt a
calibration signal segment (8000) corresponding to a known action,
such as a single footstep or a set of footsteps. The method may
then compare (8010) the calibration signal segment to expected
profiles for that known action based on assumptions that the
wearable device 4010 is worn in different positions, such as above
or below the pelvic bone or on the left or right hip. In some
embodiments, the calibration signal segment may, instead, be
compared to the expected profiles and variance of the signal
relative to the expected profile may be used to identify wearing
positions corresponding to known variances.
[0290] For example, when a worker bends over, the maximum rotation
of the wearable device 4010 will vary depending on whether it is
worn higher or lower than expected. FIG. 11A, for example, shows
the rotation of a wearable device 4010 against time for a worker
bending over when the device is properly mounted above a worker's
hip. As shown, the worker's back angle is properly measured to
achieve a maximum rotation of 37 degrees. In contrast, FIG. 11B
shows the rotation of the wearable device 4010 for the same action
when the device is mounted lower on the worker's body, showing a
maximum rotation of 14 degrees. Accordingly, when the method
identifies an improper profile, such as that shown in FIG. 11B, the
method may either trigger an alert, instruct the user to correct
the mounting position, or it may modify the algorithms or
recalibrate the device accordingly.
[0291] Accordingly, the devices 4010 are optimized to be located at
a specific region of the body, such as wrist or hip. Knowing if the
worker has located it correctly is important. Wearing the device
too high or too low, as well as too far forward on the waist,
should be corrected. Accordingly in some embodiments, a calibration
method may be implemented in order to determine if the wearing
location of the wearable device 190. In such an embodiment, the
method may first determine that an actual physical posture of a
worker wearing the wearable device 190 corresponds to a known
physical posture, as at 7000. The method then receives the first
signal generated from dynamic activity over time (at 7010) and
identifies a calibration signal segment (at 7020) corresponding to
an expected pattern for calibration activity and identifies a
device location relative to the user based on variance between the
calibration signal and the expected pattern (at 8010). In such a
method, other portions of the calibration method described may be
omitted.
[0292] Accordingly, the device location is a side of the user's
body or a height relative to the user's hips. Alternatively, the
device location may be an offset relative to a user's hip
indicating that the wearable device 190 is too far forwards or
backwards of the user's hip. The method may then alert the user if
the device location relative to the user does not correspond to an
expected device location, so that the user may adjust the device
location accordingly.
[0293] Similarly, an acceleration profile for a known activity will
vary depending on wearing position of the wearable device (4010).
For example, when a worker is walking, the resulting profile will
be different if the worker wears the device on his left hip, as
shown in FIG. 12A, than if the worker wears the device on his right
hip, as shown in FIG. 12B.
[0294] In order to increase the accuracy of the calibration method,
a worker may be instructed to perform a known action. For example,
a worker may be instructed to bend their back with or without
bending their knees in order to determine the mounting height of
the wearable device 190. The worker may also be asked to twist
their back in order to determine the maximum rotation of the
wearable device 4010 in that context.
[0295] Many features of the methods and systems described are
enhanced by associating each wearable device 190 with a specific
worker. The proper association during ensures accurate and
consistent evaluation of risk metrics, and further ensures that
measurements are associated with the correct worker.
[0296] In some embodiments, the device may be assigned to a
particular worker through a software web interface, using the
serial number of the device, the device name, label, or alias, for
example. This information is then stored on a web server and
communicated to the device. In order to confirm the association,
the device may, for example, display the worker's name and a unique
company label. Every day before work starts, the worker picks up
their associated device showing his or her name and the unique
label number.
[0297] In some embodiments, the identification of a particular
worker may be based on details within the calibration signal
segment discussed above. For example, when a worker initiates the
calibration process, the method may track a user walking for a few
steps and then analyze the user's gait in order to identify the
particular user.
[0298] In some embodiments, the wearable devices 190 each have RFID
readers to read the worker's badge or entry card and associate
themselves to that worker. This may be done on a daily basis, such
that each day a worker may pick up one of several available
wearable devices 190 and associate that device with their own
profile. Alternatively, the association may be manually created by
a worker entering their name, employee ID or other unique
identifying feature at a worker interface, so the device can
associate the data to that specific worker. In some embodiments,
this association may allow the worker to use the wearable device
190 as a key to authorize access to particular locations within a
facility or specific equipment.
[0299] In some embodiments, the data and metrics collected and
computed by the systems and methods provided can be combined with
other available data, both individual to the worker as well as
aggregated across the worker, job type, facility, company, or
industry. Typical data collection studies might involve:
[0300] Identifying industries and jobs involved with
musculoskeletal injury risk;
[0301] Examining a specified company's injuries records; and
[0302] Collecting worker motion sensor data by means of the
invented device.
[0303] Once these three steps are completed, a study operator could
assess current state of the art ergonomic models with respect to
their predictive power and limitations while designing dynamic,
sensor-based, prediction models.
[0304] Most currently used ergonomic models rely on static data
points to analyze motion, are based on data collected for only a
few days, if not hours, per employee, and per job type, and focus
on a very specific activity and do not encompass tasks' true
complexity. By using the wearable device 190 described, continuous
sensor measurements over longer time periods and across different
industries and job types, as well as more granular worker-specific
data (such as past injuries, days off work, incident rates,
behavior observation, age, gender, and medication taken),
correlations between specific repetitive motions and injury factors
may be examined and more accurate and precise predictive models may
be developed.
[0305] The results of such studies may be used to increase the
predictability of past data, and may increase the quality of, for
example, actuarial evaluations of workers for the purpose of
insurance rates. Separately, data may be used to reorganize
workplaces for increased safety and efficiency and various safety
requirements may be associated with tasks based on particular
injury risks uncovered in the data. In some embodiments, worker s
may volunteer to be monitored using the wearable device 4010 in
exchange for a reduction in their own insurance rate, and the data
acquired may be used to more granularly adjust the rate or penalize
or reward the worker.
[0306] Any model based on the dynamic data described may then
generate data that feeds back into the model. As shown in FIG. 13,
various categorized risks associate with a worker, including risks
based on the sensor data generated and evaluated using the methods
described, may be used to predict injury, absenteeism, and other
risk. Over time, the model may then be informed of actual injuries,
etc., which may then refine the model.
[0307] FIG. 14 is a flowchart illustrating a method for adjusting
insurance based on worker safety. Typically, insurance policies for
workers compensation are based on industry expectations for losses
for a particular category of worker, historical losses for a
client, and several other factors. Accordingly, risk metrics tied
to particular workers or groups of workers would be valuable in
more precisely assigning insurance risk in the industry.
[0308] The method provided initially associates a risk score (9000)
with each worker of a group of workers. While the method is
described with respect to one worker of the group of workers, each
worker in the group would typically be provided (9005) with a
wearable device 190 for use in the method, and the method would
modify the risk score associated with each worker. Typically, the
risk score is a predictive metric for predicting whether an
individual or a group has a high probability of incurring an
injury.
[0309] Accordingly, a first signal is received (9010) from a
wearable device 4010 worn by the first worker and generated by
dynamic activity of the wearable device over time. An initiation
time for a first physical activity of a first category of physical
activity performed by the first worker is then identified (9020) in
the first signal, and a first signal segment is defined (9030) in
the first signal, the first signal segment corresponding to the
time period in which the first physical activity is performed. In
some embodiments, the first signal segment is extracted from the
first signal, while in others, the first signal segment is used
directly as part of the first signal. As discussed above, the time
window for the first signal segment may be defined based on an
expected end time for the first physical activity, or it may be
determined based on details in the first signal.
[0310] Measurements of the first worker are calculated (9040) for a
time period during the first physical activity. Such measurements
are derived from and calculated based on data in the first signal
segment.
[0311] The measurements are then used to calculate (9050) an
activity risk metric from a risk model based on the measurements of
the wearer for the time period during the first physical activity,
wherein the risk metric is indicative of a risk level of the
execution of the physical activity by the first worker.
[0312] The identification of an initiation time and calculations
described above are then repeated to identify a plurality of
additional physical activities of the first category of physical
activity.
[0313] Once risk metrics are calculated and associated with a set
of physical activities, such risk metrics are used to modify the
risk score of the first worker (9060). Accordingly, if the activity
risk metrics indicate that the first workers performance of the set
of physical activities was high risk, then the risk score for the
first worker may be increased. Similarly, if the activity risk
metrics indicate that the first worker successfully minimized the
risk associated with his actions, the risk score for the first
worker may be reduced. While the risk score is discussed in terms
of a high risk score corresponding to a high risk worker, the
alternative may be possible as well.
[0314] The risk score for the first worker may then be used to
modify insurance premiums (9070) for a policy covering that worker.
Further, as discussed above, the method would typically be applied
to a group of workers. Accordingly, each worker may be provided
with a corresponding risk score, which may be modified based on
that worker's respective activity risk metrics. The risk scores for
the workers in the group may then be incorporated into actuarial
tables for the group such that insurance premiums may be calculated
or adjusted for the group.
[0315] In addition to the activity risk metric (at 9050) and the
cumulative risk metric (at 9055), the method may generate a
collective risk metric for the group of workers based on the risk
scores associated with the individual workers of the group of
workers. In such an embodiment, the insurance premium may be
calculated based on the collective risk metric.
[0316] In some embodiments, a cumulative risk metric may be
calculated (9055) for each worker based on multiple physical
activities, the cumulative risk metric being indicative of a risk
level from the activities over time, and may be used to modify the
risk score. Potential metrics for the cumulative risk metric are
discussed above. In such an embodiment, the risk score for each
worker of the group of workers may be modified based on the
cumulative risk score for the corresponding worker.
[0317] Further, the method may further comprise generating a
penalty assessed against the worker upon the calculation of a risk
metric if the risk metric indicates a high risk posture performed
by the worker.
[0318] The risk score may be modified over time based on data
collected by the system. Accordingly, the risk score may be based
on correlating motions or features derived from the motions, by way
of the activity risk metric, with injuries by workers performing
the work. This may be by machine learning algorithms or other
statistical methods. Such risk score may leverage the NIOSH and
MARRAS models, discussed above, as MARRAS has methods for
predicting whether a group has a high probability of incurring an
injury compared to a low probability group.
[0319] While the method is described generally in terms of a group
of workers, a similar method can be used to price a premium for a
single worker, whether or not that worker is part of a group.
Further, in addition to a worker's particular risk score, the price
of an insurance premium can be further based on risk associated
with a task or set of tasks performed by the worker. For example,
the method may record the full set of tasks performed by a worker
over time, and each such task may have a baseline risk level. The
combination of such risk levels can be used to generate a baseline
insurance premium utilized in calculating the worker's premium.
[0320] Using such methods, and by correlating geometric and
population features with probability of injury, an estimate of the
frequency and severity of claims can be made.
[0321] If factors implemented at a facility reduce the probability
of injuries to an individual or group that would affect the
expected cost of injuries at that site. Such actions could then be
rewarded by insurance providers by reducing the cost of a premium
or providing a discount on a future premium payment.
[0322] Modifications of premium prices may then be made by updating
injury rates based on the risk scores calculated by this method.
The modification can be done in real time or after a period of
time.
[0323] While the discussion of premium prices is in terms of group
rates for a group of workers, the method may similarly be applied
to a single worker, where a risk score for the worker is used to
calculate or adjust a premium for that worker.
[0324] In some embodiments, the risk associated with performance of
activities by workers can be used to adjust payments or assign
bonuses to workers. Accordingly, the wearable device can be used to
monitor an employee's postures while engaged in manual labor, and
to collect data based on the type of motions made, and the quantity
and frequency of motions. The data may then be compared to industry
quotas or other comparable individuals and then used to affect
variable compensation or job assignments.
[0325] In one embodiment, the method is for incentivizing risk
reduction during physical activities, as shown in FIG. 15, and each
worker is assigned a wearable device, such as those discussed
above. Each worker may be assigned a base risk score (9100) at the
beginning of a shift, or at the beginning of a longer period of
time over which the method is implemented. The risk score is used
to calculate a rate of payment for the worker. In some embodiments,
a plurality of risk scores may be associated with a worker, such
that each risk score is associated with a different category of
physical activity to be performed by the worker. For example, a
first risk score may be associated with lifting actions, while a
second risk score may be associated with pushing actions or
equipment operation. The method then first receives a first signal
(9105) from the wearable device generated from dynamic activity of
the wearable device over time. The method then identifies an
initiation time (9110) for a first physical activity of a first
category of physical activity performed by the worker wearing the
wearable device.
[0326] The identification of an initiation time (at 9110) can take
a variety of forms. In some embodiments, the identification is by
identifying a signature in the first signal itself. In other
embodiments, the worker may indicate that they are initiating a
physical activity. For example, a worker may scan a code on a box
prior to lifting or otherwise manipulating the box. Alternatively,
the identification may be by a server in communication with the
wearable device, and the first category of physical activity may be
identified based on a schedule associated with the worker and
stored on the server.
[0327] Once the initiation time is identified (at 9110), a first
signal segment in the first signal may be defined (at 9120), the
first signal segment corresponding to the portion of the first
signal associated with the timing of the first physical activity.
Measurements of the worker are then calculated (at 9130) for a time
period following the initiation time corresponding to the first
physical activity from the first signal segment.
[0328] After a physical activity is performed by the worker, a
payment is generated (9140) and provided to the worker based on a
calculated rate associated with the first category of physical
activity. The calculated rate is based on both the category of
physical activity performed and the risk score associated with
worker for that particular category of physical activity. As noted
above, the risk score is specific to the category of physical
activity. Accordingly, when a user performs a lift, for example,
they may identify the initiation of the lift by scanning a box to
be lifted and then perform the lift. After performing the lift, the
worker will be assigned a payment calculated based on the fact that
the activity was a lift and the workers personal risk score
associated with lifting.
[0329] Micropayments per task are already common practice as many
employers pay per case lifted or scanned, as opposed to by the
hour. The device may display metrics to users, such as productivity
metrics (i.e., cases lifted) or payment accrued, as well as
performance metrics (i.e., cases lifted per hour) and goals (i.e.,
target cases per hour).
[0330] An activity risk metric is then generated (9150) from a risk
model based on the measurements of the wearer for the time period
during the physical activity, the activity risk metric being
indicative of a risk level of the execution of the physical
activity by the wearer. The activity risk metric may be any of the
metrics discussed above that quantify the risk of a specified
physical activity.
[0331] After the activity risk metric is generated (at 9150), the
metric may be used to modify the risk score (at 9160) associated
with the worker and the first category of physical activity. In
this way, the risk score may be adjusted to reflect the risk
associated with the particular worker performing the particular
type of task. If the activity risk metric reflects a low risk
performance of the physical activity by the worker, the risk score
may be modified such that a larger payment is generated (at 9140)
for future activities. Similarly, if the activity risk metric
reflects a high risk performance of the physical activity, the risk
score may be modified such that future payments are reduced.
[0332] Once the risk score is modified (at 9160), the method is
repeated, such that an initiation time for another physical
activity is detected (at 9110), measurements are calculated (at
9130), payments are generated (at 9140), and another activity risk
metric is defined (at 9150) to identify and score a plurality of
additional physical activities of the first category of physical
activity.
[0333] Although the discussion herein provides for generating
payment prior to analyzing a physical activity being performed, in
some embodiments, for each physical activity performed, the payment
is generated (at 9140) based on the risk score at the time of the
activity. In some embodiments, the activity risk metric may be
calculated and the risk score modified before generating payment
for any particular physical activity.
[0334] In embodiments where each worker has a plurality of risk
scores, each associated with different categories of physical
activities, the modification of the risk score associated with one
category would not affect the risk score of a different category.
Accordingly, if a worker has good posture for lifts, for example,
they may get increased payments for such lifts regardless of their
performance of other activities, such as driving.
[0335] Typically, each worker will have a distinct set of risk
scores for various physical activities. In some embodiments,
insurance premiums may be modified based on a complete set of risk
scores associated with a grouping of workers.
[0336] In some embodiments, in addition to activity risk metrics
associated with each worker (at 9150), the method may use either
the risk metric or the underlying measurements or signal segments
to calculate a cumulative risk metric (9170) indicative of a risk
level from multiple physical activities over time. In such an
embodiment, the worker may have an associated cumulative risk
threshold, such that when the cumulative risk metric is above the
threshold, they are at an increased risk generally. In such an
embodiment, prior to generating payment (at 9140), the method may
determine if the cumulative risk metric is above the threshold
(9180). If the cumulative risk metric is above the threshold, a
cumulative modification may be applied to the payment, such that
payment is reduced. The cumulative modification would be removed
from the payment if the cumulative risk metric is brought back
below the threshold, such that the payment is increased.
[0337] Similarly, in some embodiments, the cumulative risk metric
may be calculated across multiple physical activities over time and
a bonus payment may be applied to a user if the cumulative metric
stays below the cumulative risk threshold for a defined period of
time.
[0338] In some embodiments, a worker's overall wages could be
comprised of fractional payments made for completing tasks and
events in the industrial workplace, such as the quantity of boxes
lifted or sorted or the number of deliveries made. Specific tasks
and biomechanics events may be valued different based on difficulty
and economic value to the employer, or by the quality of work done.
Such worker payments may be automated and use a programmable
contract designed by the employer, and that contract may use fiat
currency or blockchain currency to automatically provide payments
to workers instantly or after a set period.
[0339] In some embodiments, worker job and task assignments would
be automatically determined based on productivity data, allowing
for live and automatic adjustments to job instructions that could
be communicated back to workers via messaging to wearable devices
or other equipment. Accordingly, worker messaging could communicate
to workers to switch tasks to a new task more suited to their
biomechanics, or more urgent based on operational needs.
[0340] The productivity and safety data generated by the system and
method described may be used to automate worker promotions and
company reporting structure. Workers with higher productivity or
who are more skillful or safer may be automatically promoted to
tasks requiring higher skills or more responsibility.
[0341] In addition to modifying payment levels to workers, the data
can be used otherwise increase productivity and morale using
gamification methods. For example, the device may have a screen
where information can be shown. A measure of productivity may be
presented on the screen so that the worker can see their
productivity level. For example, a measure of productivity could be
a number of tasks performed, such as a number of items picked, a
number of orders fulfilled, or a number of lifts performed, etc.
That measure can be automatically detected by the device, as
discussed above, or it may be obtained from a server or otherwise
retrieved from a workplace management system.
[0342] Further, a goal can be set and shown to indicate to the
worker a desired level of the productivity metric. The goal can be
based on a unit of time, for example per day or per hour. By
displaying productivity in real-time, and being able to compare it
to a goal, workers can see how they are performing and can modify
their performance accordingly.
[0343] In addition, a competitive rank can be displayed on the
screen, showing how the worker is performing compared to their
peers in the same job or in the same facility or company. In some
embodiments, workers can be ranked by number or rate of safe
postures, and may be given a bonus based on such rank. Where
workers are ranked, a large on site display may be provided to
display ranks, provide leaderboards, highlight specific workers,
etc.
[0344] Accordingly, the device display may present a number of
metrics, such as numbers of safe and risky postures, safety
performance against goals, steps, calorie estimation, and
competitive data, such as rank in a competition, data by teams, and
the like. The data may be shared with other workers by email,
website, a companion app, social media, or the like. In some
embodiments, custom content may be automatically shared with
workers based on worker data, such as personalized training videos,
safety or productivity improvement tips, praise, reward
notifications, and the like. Such sharing may be on the wearable
device display, by email, by SMS, or by internet.
[0345] The goal assigned to the worker can be static, that is does
not change over time. For example the goal of taking 10,000 steps
per day to stay healthy.
[0346] Alternatively, the goal can also be dynamic, that is, it
changes over time, or based on the progress made by the wearer. For
example, a goal can be updated if a worker exceeds it for 3 days in
a row. That goal could become higher, to challenge the worker to
increase that metric. Or if the goal refers to a metric which is
desired to be minimized, like the number of high-risk postures, it
could be reduced as workers reduce their daily score or metric as
it related to high-risk postures.
[0347] Goals can also be changed based on interaction by the
user--for example if a worker presses the button on the wearable to
view their data frequently or is wearing their device frequently,
it could be judged that they are engaged and the goal can be
modified accordingly.
[0348] Further, if workers are showing signs of fatigue, or if
incidents of high risk postures are increasing, or when a specific
time of day is approaching, such that the worker typically performs
higher risk activities, the productivity goals may be reduced.
[0349] Examples of strategies for dynamic updating of goals are
shown in FIG. 16.
[0350] All the above information can also be sent to a separate
system, for example a warehouse management system or a computer
system in the workplace and displayed on the screen. For example
the performance and goal of workers can be sent to a separate
computer and displayed on a screen for workers to see.
[0351] Wearable devices referenced throughout this disclosure are
used to monitor worker postures and other high-risk motions and to
provide workers with immediate feedback to correct the posture or
high-risk motion. The wearable devices may also be used to collect
data to determine the risk of injury over time. In order to assess
such risks and provide feedback, the wearable device must be
associated with the worker wearing the device for processing.
[0352] Generally, a worker beginning his shift must pick a wearable
device already assigned to him, or must follow a procedure to
assign a new wearable device to himself. Accordingly, in some
embodiments, the device may be assigned to the worker and the
worker may then be instructed as to which device to select. In
other embodiments, the device may be assigned to the worker
immediately before the worker taking the device. In other
embodiments, the device may automatically detect which worker it is
associated with.
[0353] Accordingly, a system for assigning a wearable device to a
worker may comprise multiple wearable devices to be assigned to
multiple worker. In such a case, the devices may be provided with
docking locations, and each docking location may be associated with
an identity of the wearable device located at the docking
location.
[0354] Each docking location may then have an indicator associated
with it, such that the indicator identifies the assigned identity
for the one of the plurality of wearable devices docked at the
corresponding docking location.
[0355] Accordingly, in a situation where a worker has an assigned
device, and needs to know where to find it among many other
devices, each device may be located in accordance with some
organizational scheme, and each docking location may thereby
identify the wearable device docked at that location. In such an
embodiment, devices may be, for example, located in color coded
kiosks or carts. Each device is then located at specific charging
well, or docking locations.
[0356] The device may then be uniquely located within the
organizational scheme. For example, the device may have a color and
a number, with the color identifying a charging bank or kiosk, and
the number identifying a specific docking location within that
kiosk. A worker may then be instructed to take the wearable device
from a specified location within the organizational scheme.
[0357] In order to implement such a system, as shown in FIG. 17A, a
work environment is first provided with a plurality of wearable
devices (9200) to be assigned to a plurality of workers. The
environment is then provided with a plurality of docking locations
(9210) for docking the wearable devices, and each docking location
is provided with an indicator (9220), where the indicator
identifies an assigned identity for the wearable device docked at
the corresponding docking location. In some embodiments, the
assigned identity may be a particular worker or user to whom the
associated wearable device is assigned.
[0358] A worker utilizing the system may then be assigned wearable
device containing a specified indicator, and may then take the
wearable device from the corresponding docking location (9230). In
some embodiments, the assigned identity is a scannable code or a
readable code, such that when the worker selects a wearable device
from a docking location, they can scan the scannable code with a
secondary device or enter the code into a device, such as a
smartphone or a standalone scanner, thereby assigning the wearable
device to himself. In some embodiments, the worker is permanently
assigned a wearable device docking location, and the location may
be identified on a workers badge or sticker.
[0359] The worker may then utilize the wearable device over the
course of the day in accordance with the any of the other methods
discussed herein. Upon the conclusion of a work day, the worker may
then deposit the wearable device at a docking location (9240),
where the docking location is not necessarily the same location
that he initially took the wearable device from.
[0360] Accordingly, where the wearable device is returned to a
docking location other than the docking location it has been
previously mapped to, the wearable device is reprogrammed (9250) to
correspond to the identify identified by the corresponding
indicator at the new docking location. In such a way, it is
prepared for a worker who may take the wearable device (at 9230) in
a following work session.
[0361] In some embodiments, a worker may be expected to return the
wearable device to the originally identified location, so that the
worker uses the same device on consecutive days. In such an
embodiment, the identity of the wearable device may be displayed on
a screen of the device to help the user remember where to place the
device.
[0362] Alternatively, the worker may be directed by an indicator,
such as an on screen display from the wearable device, to place the
device at a specified drop off location (9235). In this way, the
worker may be instructed to return the device to a docking location
selected by the system from a set of unoccupied docking
locations.
[0363] In some embodiments, rather than the indicator being
associated with a docking location, it may be associated with a
particular device. Accordingly, the device may have a permanently
assigned label, or a machine readable indicator code may be
presented on a display for the device. A worker may then select any
wearable device from a set of wearable devices at docking
locations. The worker may then scan the machine readable code from
the device or display. This may be by way of a bar code scanner or
QR code scanner on a tablet or smartphone or other portable device.
Alternatively, it may be by way of an RFID tag, a Bluetooth
connection, an NFC connection, or another form of digital handshake
or coding using either the portable device or the worker's badge.
If the tablet or smartphone is not already associated with the
worker, the worker may then select their name or otherwise enter
their identity at the tablet or smartphone. Alternatively, a worker
may scan their worker badge at the portable device. The system may
then assign the worker to the device, and the worker can begin
work. At the end of the day, the device is returned to any location
on the dock. If not wirelessly connected to a server, the device
may upload data at the docking location. The indicator may then be
reset for the following day, if necessary.
[0364] Where a worker uses their badge to associate a wearable
device with themselves, the ID must be a human readable or machine
readable passive or active ID. The ID can be included in a workers
employee access badge, phone, wallet, clothing, or the like. In
such an embodiment, a worker association with a wearable device
could be recorded at a server and in an appropriate database. This
may be by way of the wearable device itself, or it may be by way of
a kiosk associated with a docking location capable of reading the
ID on the device as well as the employee ID. Data integrity in a
large workplace is important, since data can be associated with any
one of hundreds or thousands of workers.
[0365] In some embodiments, the wearable device detects some
element of the worker, such as an RFID or Bluetooth based ID,
automatically once the worker takes the wearable device. For
example, when the worker wearing the device walks through a door
which uses proximity technology to detect the employee through
their badge or phone or the like as well as the wearable device,
and thereby associates the device and worker. Similarly, the
wearable device may automatically pair itself with the worker's
smartphone or other portable device using Bluetooth or NFC, thereby
associating itself with the worker.
[0366] An alternative method for assigning a wearable device to a
worker is shown in FIG. 17B. As shown, the method may first
receive, at a processor, a first signal from the wearable device
(9300). The method may then identify, in the first signal, a user
specific signal segment (9310) corresponding to a performance of a
known physical activity. For example, the method may identify a
user walking, such that the signal signature associated with the
walk may be uniquely associated with a specific worker.
[0367] The method may then identify a plurality of sample signal
segments (9320) corresponding to the known physical activity, with
each of the sample signal segments corresponding to a performance
of the known physical activity by a different user. Each of the
sample signal segments is there compared (9330) to the user
specific signal segment.
[0368] The method then identifies (9340) a first sample signal
segment corresponding to the user specific signal segment, the
first sample signal segment corresponding to the performance of the
known physical activity by the worker. In this way, the method
identifies a particular user that the user specific signal segment
corresponds to. Once identified, the method then associates (9350)
the wearable device with the worker.
[0369] As noted above, the known physical activity may be the
worker walking. Accordingly, the sample signal segments may
correspond to users having distinct gaits, such that the user
specific signal segment is identified based on a unique gait
signature for that worker.
[0370] In some embodiments, a database may be created during an
initial setup phase to generate the sample signal segments for all
workers using the system and method.
[0371] Embodiments of the subject matter and the operations
described in this specification can be implemented in digital
electronic circuitry, or in computer software, firmware, or
hardware, including the structures disclosed in this specification
and their structural equivalents, or in combinations of one or more
of them. Embodiments of the subject matter described in this
specification can be implemented as one or more computer programs,
i.e., one or more modules of computer program instructions, encoded
on computer storage medium for execution by, or to control the
operation of, data processing apparatus. Alternatively or in
addition, the program instructions can be encoded on an
artificially generated propagated signal, e.g., a machine-generated
electrical, optical, or electromagnetic signal that is generated to
encode information for transmission to suitable receiver apparatus
for execution by a data processing apparatus. A computer storage
medium can be, or be included in, a computer-readable storage
device, a computer-readable storage substrate, a random or serial
access memory array or device, or a combination of one or more of
them. Moreover, while a computer storage medium is not a propagated
signal, a computer storage medium can be a source or destination of
computer program instructions encoded in an artificially generated
propagated signal. The computer storage medium can also be, or be
included in, one or more separate physical components or media
(e.g., multiple CDs, disks, or other storage devices).
[0372] The operations described in this specification can be
implemented as operations performed by a data processing apparatus
on data stored on one or more computer-readable storage devices or
received from other sources.
[0373] The term "data processing apparatus" and like terms
encompass all kinds of apparatus, devices, and machines for
processing data, including by way of example a programmable
processor, a computer, a system on a chip, or multiple ones, or
combinations, of the foregoing. The apparatus can include special
purpose logic circuitry, e.g., an FPGA (field programmable gate
array) or an ASIC (application specific integrated circuit). The
apparatus can also include, in addition to hardware, code that
creates an execution environment for the computer program in
question, e.g., code that constitutes processor firmware, a
protocol stack, a database management system, an operating system,
a cross-platform runtime environment, a virtual machine, or a
combination of one or more of them. The apparatus and execution
environment can realize various different computing model
infrastructures, such as web services, distributed computing and
grid computing infrastructures.
[0374] A computer program (also known as a program, software,
software application, script, or code) can be written in any form
of programming language, including compiled or interpreted
languages, declarative or procedural languages, and it can be
deployed in any form, including as a standalone program or as a
module, component, subroutine, object, or other unit suitable for
use in a computing environment. A computer program may, but need
not, correspond to a file in a file system. A program can be stored
in a portion of a file that holds other programs or data (e.g., one
or more scripts stored in a markup language document), in a single
file dedicated to the program in question, or in multiple
coordinated files (e.g., files that store one or more modules, sub
programs, or portions of code). A computer program can be deployed
to be executed on one computer or on multiple computers that are
located at one site or distributed across multiple sites and
interconnected by a communication network.
[0375] The processes and logic flows described in this
specification can be performed by one or more programmable
processors executing one or more computer programs to perform
actions by operating on input data and generating output. The
processes and logic flows can also be performed by, and apparatus
can also be implemented as, special purpose logic circuitry, e.g.,
an FPGA (field programmable gate array) or an ASIC (application
specific integrated circuit).
[0376] Processors suitable for the execution of a computer program
include, by way of example, both general and special purpose
microprocessors, and any one or more processors of any kind of
digital computer. Generally, a processor will receive instructions
and data from a read only memory or a random access memory or both.
The essential elements of a computer are a processor for performing
actions in accordance with instructions and one or more memory
devices for storing instructions and data. Generally, a computer
will also include, or be operatively coupled to receive data from
or transfer data to, or both, one or more mass storage devices for
storing data, e.g., magnetic, magneto optical disks, or optical
disks. However, a computer need not have such devices. Moreover, a
computer can be embedded in another device, e.g., a mobile
telephone, a personal digital assistant (PDA), a mobile audio or
video player, a game console, a Global Positioning System (GPS)
receiver, or a portable storage device (e.g., a universal serial
bus (USB) flash drive), to name just a few. Devices suitable for
storing computer program instructions and data include all forms of
non volatile memory, media and memory devices, including by way of
example semiconductor memory devices, e.g., EPROM, EEPROM, and
flash memory devices; magnetic disks, e.g., internal hard disks or
removable disks; magneto optical disks; and CD ROM and DVD-ROM
disks. The processor and the memory can be supplemented by, or
incorporated in, special purpose logic circuitry.
[0377] To provide for interaction with a user, embodiments of the
subject matter described in this specification can be implemented
on a computer having a display device, e.g., a CRT (cathode ray
tube) or LCD (liquid crystal display) monitor, for displaying
information to the user and a keyboard and a pointing device, e.g.,
a mouse or a trackball, by which the user can provide input to the
computer. Other kinds of devices can be used to provide for
interaction with a user as well; for example, feedback provided to
the user can be any form of sensory feedback, e.g., visual
feedback, auditory feedback, or tactile feedback; and input from
the user can be received in any form, including acoustic, speech,
or tactile input. In addition, a computer can interact with a user
by sending documents to and receiving documents from a device that
is used by the user; for example, by sending web pages to a web
browser on a user's client device in response to requests received
from the web browser.
[0378] Embodiments of the subject matter described in this
specification can be implemented in a computing system that
includes a back end component, e.g., as a data server, or that
includes a middleware component, e.g., an application server, or
that includes a front end component, e.g., a client computer having
a graphical user interface or a Web browser through which a user
can interact with an implementation of the subject matter described
in this specification, or any combination of one or more such back
end, middleware, or front end components. The components of the
system can be interconnected by any form or medium of digital data
communication, e.g., a communication network. Examples of
communication networks include a local area network ("LAN") and a
wide area network ("WAN"), an inter-network (e.g., the Internet),
and peer-to-peer networks (e.g., ad hoc peer-to-peer networks).
[0379] The computing system can include clients and servers. A
client and server are generally remote from each other and
typically interact through a communication network. The
relationship of client and server arises by virtue of computer
programs running on the respective computers and having a
client-server relationship to each other. In some embodiments, a
server transmits data (e.g., an HTML page) to a client device
(e.g., for purposes of displaying data to and receiving user input
from a user interacting with the client device). Data generated at
the client device (e.g., a result of the user interaction) can be
received from the client device at the server.
[0380] While this specification contains many specific
implementation details, these should not be construed as
limitations on the scope of any inventions or of what may be
claimed, but rather as descriptions of features specific to
particular embodiments of particular inventions. Certain features
that are described in this specification in the context of separate
embodiments can also be implemented in combination in a single
embodiment. Conversely, various features that are described in the
context of a single embodiment can also be implemented in multiple
embodiments separately or in any suitable subcombination. Moreover,
although features may be described above as acting in certain
combinations and even initially claimed as such, one or more
features from a claimed combination can in some cases be excised
from the combination, and the claimed combination may be directed
to a subcombination or variation of a subcombination.
[0381] Similarly, while operations are depicted in the drawings in
a particular order, this should not be understood as requiring that
such operations be performed in the particular order shown or in
sequential order, or that all illustrated operations be performed,
to achieve desirable results. In certain circumstances,
multitasking and parallel processing may be advantageous. Moreover,
the separation of various system components in the embodiments
described above should not be understood as requiring such
separation in all embodiments, and it should be understood that the
described program components and systems can generally be
integrated together in a single software product or packaged into
multiple software products.
[0382] While the present invention has been described at some
length and with some particularity with respect to the several
described embodiments, it is not intended that it should be limited
to any such particulars or embodiments or any particular
embodiment, but it is to be construed with references to the
appended claims so as to provide the broadest possible
interpretation of such claims in view of the prior art and,
therefore, to effectively encompass the intended scope of the
invention. Furthermore, the foregoing describes the invention in
terms of embodiments foreseen by the inventor for which an enabling
description was available, notwithstanding that insubstantial
modifications of the invention, not presently foreseen, may
nonetheless represent equivalents thereto.
* * * * *