Transport for London (TfL) used a proactive risk management approach to identify the ergonomic risk factors associated with operating trains. TfL shares methods and lessons from their journey to support other rail organisations.

What risk did you address?

This work focused on the ergonomic risk factors associated with operating London Underground (LU) trains. There are several musculoskeletal (MSK) health issues that can arise or be exacerbated by:

  • poor train cab design, e.g., interior trim and hard points restricting space
  • how users interact with the controls within the cab, e.g., poor location and repetitive use
  • seat set-up, e.g., inadequate adjustment for range of users). 

This risk assessment would enable us to:

  • identify the risk factors present within train operator cabs for different rolling stock
  • estimate the likelihood that these risks impacted on musculoskeletal health
  • mitigate the risks identified.

What you to investigate work-related MSD health risk faced by train drivers?

A better understanding of the risks faced by drivers, and how to mitigate these, should result in a reduction in MSD-related absenteeism. In 2012, RSSB reviewed existing information, tools, and processes to determine whether they are appropriate to assess and manage MSD risk in train drivers. The Musculoskeletal Risk Assessment Tool for train drivers (MAT) was subsequently launched in 2012 and made available to RSSB members.

In 2014, the Office of Rail and Road presented its position on MSDs in a paper. It endorsed identifying potential work-related MSD risks at the earliest opportunity using suitably recognised assessment tools. Until this point there had been no consistent, comprehensive documentation of the ergonomic risk factors associated with operating a train in the rail industry. Ergonomics reviews had typically been reactive to a raised issue relating to MSDs.

There were six different types of passenger train rolling stock on the network, the oldest of which was designed more than 50 years ago. Different types of LU train have different cab layouts and operating methods, with different potential causes of MSD risks. 

How did you plan and design the intervention?

A trial was carried out to assess the feasibility of using the MAT in the cab. The trial highlighted discrepancies in the measurement. A review of these found they could largely be eliminated by ensuring that:

  • an agreement was made about the measurement points on the interface prior to testing
  • a purpose-built rig was designed and made by the LU for an accurate reproduction of the measurement points
  • a standard tape measure was replaced with a laser range finder
  • a consistent team (physiotherapist and human factors engineer) carried out the measurements.

MAT was then applied across three different cabs for each of the six different rolling stocks. Following the physical measurements, a CCTV system was set up in the train cab to allow remote viewing of the train operator operating the train. Three different train operators were used on each line to represent a range of physical dimensions of train operators.

This was the best way to correctly observe the train operator without causing distraction. The method was agreed in advance with the train operators involved, management, and unions. This helped encourage normal train operator behaviour, which enabled the identification of known and unknown risk factors.

This video footage was used to assess the train operators’ positioning in the cab and allowed for a more accurate application of the Health and Safety Executive’s Assessment of Repetitive Tasks tool.

How did you reduce the risks?

The assessment did not find any high-risk issues in the train operator’s cabs. However, it highlighted areas which could present MSD risk to train operators given their physical dimensions. For instance, cabs that are more suited to a smaller user may present problems for taller users when setting up.

Guidance documents and instructional videos were produced for each rolling stock train cab. These inform the train operators on correct set-up and explain what they can do to reduce the risks. It was agreed that training would be provided to new train operators and, for an agreed period, through yearly refresher training. Additionally, a train cab set-up checklist is included within the Competency Management System.

This process equipped us with a clearer understanding of the potential issues with each rolling stock cab. Additionally, it can be used by the physiotherapy team when treating train operators experiencing MSD issues.

How will you evaluate the intervention? 

We will continue to collect and monitor data on the number of:

  • referrals to occupational health and wellbeing physiotherapy with discomfort caused by cab posture or positioning
  • train operators requesting to move lines, and stock, due to MSD factors related to the cab.

What challenges did you face?

TfL has been incredibly supportive of this work. Management, operators, and trade unions recognise that it is the right action to take. The challenge has been finding the time in an already tight training schedule to facilitate this. But the LU internal training department has worked hard to get it included.

What has the impact been so far?

The information gained from this work will better inform train operators of the type of train cab that better suits their physical dimensions. It will also provide them with information to manage MSD risks.

Being able to carry out the assessment across different cabs has provided TfL with valuable findings. The findings are influencing the design of cabs in newly commissioned deep Tube trains. They are also serving to help educate train stock suppliers about the factors that need to be assessed when designing train cabs for LU.