Manual materials handling tasks are the main risk factors for the work-related musculoskeletal disorders. Many assistant tools for manual materials handling are being used in various kind of industries. One of them is a 4-wheeled cart which is widely used in manufacturing factories, hospitals, etc. The major force required to control the 4-wheeled cart is pushing and pulling. There are two types of handles being used for the 4-wheeled cart : vertical type (two vertical handles), and horizontal type (one horizontal handle). This study tried to investigate the pushing forces and subjective discomforts (hand/writst, shoulder, low back, and overall) of the two handle types with different handle height and distance conditions. Twelve healthy male students (mean age = 23.4 years) participated in the experiment. The independent variables were handle angle (horizontal, vertical), handle height (low, medium, high), and handle distance (narrow, medium, wide). The full factorial design was used for the experiment and the maximum pushing forces were measured in 18 different conditions (2×3×3). Analysis of variance (ANOVA) procedure was conducted to test the effects of the independent variables on the pushing force and discomfort levels. Handle height and angle were found to be the critical design factors that affect the maximal pushing forces and subjective discomfort. In the middle height, subjects exerted higher pushing forces, and experience lower discomfort levels compared to the high, and low height. There was no statistical influence of the handle distance to the pushing forces and subjective discomfort levels. It was found out that the effects of the handle angle (horizontal and vertical) on both pushing force and subjective discomfort were statistically significant (p < 0.05). The vertical handle revealed higher pushing force and lower discomfort level than the horizontal handle. The reason for that was thought to be the different postures of the hand when grasping the handles. The horizontal handle induced pronaton of the hand and made hand posture more deviated from the neutral position.

Among various manual materials handling tasks, pushing/pulling was known to be one of the risk factors for the low back and shoulder musculoskeletal disorders (MSDs). This study was conducted to find out an optimal solution set of the handle height and distance for 4-wheel cart with two vertical handles. Ten male college students participated in the pushing force measurement experiment. The face-centered cube design, one of the central composite designs, was applied for the experiment, and the isometric voluntary pushing force was measured in 9 treatment conditions. The second order response surface model was predicted by using the pushing strength as a response variable, and the handle height and distance as independent factors. According to the 2nd order response model, the handle height and distance showed nonlinear relationship with the isometric pushing strength. To maximize the 2nd order response model (pushing force), the handle height and distance were optimized. The optimal handle height was 'xyphoid process height - stature’, and the optimal handle distance was ‘1.25*shoulder width’. When calculated using the anthropometric data of the subjects of this study, the optimal handle height was 115.4 ± 3.4 cm, slightly higher than the elbow height, and the handle distance was 52.9 ± 2.3 cm.