This invention relates to an ergonomically designed check-out counter system for supermarket and merchandising industries characterized by provisions for differences in human heights, hand and position of operators and for ease in handling of merchandise to reduce fatigue and injury to operators while providing maximum productivity under both light and heavy through put requirements.

Within the supermarket and merchandising industries, many different styles of check-out counter systems are in use. With increasing labor costs and improved data systems, the pressure for productivity at the check-out location of these industries has increased dramatically.

In the late 1970s, mechanical cash registers were being replaced by integrated points of sales terminals, leading to different work procedures, increased work rates, and reduced labor requirements. Significant gains in productivity were realized. The resulting check-out counter systems have been typically designed to move products and to provide the customer with needed services. However, little attention has been given to the cashiers who have operated these check-out counter systems. The human doing the job is required to adapt to the system. Apparent incompatibilities between the cashier, the work procedures and the check-out counter design have led to increased health complaints and workers' compensation claims and disability lawsuits. The major time loss claim is due to over exertion leading to strains and sprains of the lower back and upper extremities. The real tragedy is that many workers in this environment are suffering from permanently disabling injuries.

It is only in recent years that certain of these injuries have been identified as work related. Biomechanical studies indicate that the lower back is vulnerable to continual over stress damage during even moderate load handling, but that the symptoms may not manifest themselves until later in life. Carpal tunnel syndrome - a present day "buzz word" in this industry - and related injuries such as tendinitis, tenosynovitis, and De Quervain's Disease are apparently caused by injuries which build up gradually over time before symptoms begin to appear. Tasks which are highly repetitive in nature dramatically increase the risk of injury. Fatigue also appears to be one of the underlying causes of many of the symptoms experienced by cashiers at check-out counter systems. There are many human factors affecting the task performed at check-out counter systems, but there is little "hard" data to work with. It is known that certain repetitive tasks have the potential to cause cumulative trauma disorders, but critical levels of repetitiveness have not been determined, and critical force levels are not known. Although some individuals are far more susceptible to repetitive injuries than others, there is no reliable method of determining who is the most vulnerable.

During the last few years, there has been increasing interest throughout the supermarket and merchandising industries in the application of ergonomic principles to the check-out counter system. Retail clerks' unions are becoming active in this area and OSHA has brought the supermarket front-end under scrutiny. However, the supermarket check-out counter systems present ergonomic problems which do not lend themselves to easy solutions.

Nearly all check-out counter systems in the United States and Canada are designed so that cashiers must work in a standing posture. When seating is not available at the check-out counter systems, cashiers report discomfort and pain in the legs, apparently caused by prolonged standing. In contrast, most check-out counter systems in Europe and some other parts of the world are designed so that the cashiers work in a seated position. Studies have shown that prolonged sitting is associated with increased rates of low-back pain, probably caused by rotation of the pelvis.

Working continuously in either a standing or seated position has disadvantages. When working in a standing posture, muscles in the legs, feet and lower back must work constantly to maintain this posture. Heavy loads are placed on the feet. As each major muscle group remains tensed, circulation through these muscles is reduced, nutrient flow to the muscles is restricted, and the chemical products of fatigue build up in the tissues. On the other hand, when working continuously in a seated position, continuous tensing of specific muscle groups occurs. Circulation to the legs is further restricted by pressure from the chair seat. When assuming a seated posture, the lower lumbar curve of the back becomes nearly straight and this rotates all of the vertebra in this section of the back out of their neutral position into a position in which the torso loads are concentrated on the front of each vertebra and disc. The net result is a reduction of the lower back strength of about 30%. When working in a seated position it is physically difficult to handle bulky items and it is impossible to use the legs to assist in lifting heavy items.

In addition, there are two basic types of check-­out counter systems, i.e. customer unload and cashier unload. With customer unload check-out counter systems, the customers places his order on the top of the check-out counter so that the cashier can record the price of each item. The top of the check-out is usually provided with a conveyor belt to transport the order to the cashier. The top surface of the customer unload check-out is typically to 38 inches above the surface on which the cashier is standing. With cashier unload check-out counter systems, the cashier removes the customer's order from the shopping cart and records the price of each item. The top surface of the cashier unload check-out is typically 29 to 32 inches above the surface on which the cashier is standing.

With both systems, after the price of each item has been recorded, the customer's order is placed in boxes, paper bags or plastic bags by the cashier or by a professional bagger. The bagging operation is performed on the check-out surface, on a special bagging shelf or platform that is part of the check-out counter system, or on bagging racks which can be placed on either of the above mentioned surfaces or suspended from the end of the check-out counter system. In all cases the bagging surface is fixed at one height above the floor.

In that regard, anthropometric data reveals that the sth percentile female is just under 5 feet (1.52m) tall and that the 95th percentile male is over 6 feet 2 inches (1.88m) tall. When the surface of a work place is at a correct height, the operator is able to work with the upper arms hanging relaxed and the wrist 1 to 4 inches (2.54 to 10.16cm) lower than the elbow. It has been found by applying anthropometric data to these requirements that the working surface for a 5 foot (1. 52m) tall person should be 34 to 36 inches (86.4 to 91.4cm) high and the working surface for a 6 foot 2 inch (1.88m) person should be 41 to 43 inches (104.1 to 109.2cm) high. To applicant's knowledge, no check-­out counter systems have heretofore recognized or made any allowances for these requirements and differences in human heights of the operator.

All check-out counter systems must have a keyboard to enter price data. These keyboards have been placed in many different locations in check-out counter systems. In some check-out counter systems, the keyboards have been made adjustable up and down relative to the check-out counter and sometimes the angle can be adjusted. However, to applicant's knowledge no one has ever taken into consideration the fact that many people are left-handed. The best location for a keyboard from an ergonomic viewpoint is directly in front of the cashier, at a height and angle that allows the cashier to operate the keyboard with his upper arm hanging in a relaxed position and the wrist within 15 degrees of a neutral (straight) posture. Keyboards mounted in this way are typically placed directly in front of the cashier's right shoulder, since the majority of our population are right-handed. For a left-handed operator to use this keyboard, the left arm must be extended across in front of the body and the left wrist must be bent back to the left at an uncomfortable angle.

It has been found that for maximum productivity when business is light, the most cost-effective and productive system of processing goods at the check-out counter is one in which the cashier graps each item, records its price (either manually with the keyboard or with the use of a laser scanner), then places it directly in a bag for the customer. This is referred to as "direct bagging". It has the advantage of using only one worker and of handling each item only once. On the other hand, when business becomes heavy, it is advantageous to be able to add manpower, such as a bagger, to the process in order to speed customers through the check-out as fast as possible. Prior check-­out counter systems have not been specifically designed to best accommodate both of these procedures.

It is an object of this invention to tackle the above problems and to provide an ergonomically designed check-­out counter system which provides an environment for the cashier and bagger in which provision has been made for the differences in human heights, hand and position of operators and for ease in handling of merchandise to reduce fatigue and injury to operators while providing for maximum productivity under both light and heavy through put requirements in the system.

According to one aspect of the present invention, it is proposed that a check-out counter system should incorporate an adjustable floor which will place a cashier of any stature at a comfortable working height. In addition, bagging racks may advantageously be provided at the end of the check-out counter system to hold plastic grocery bags for use by a bagger and means are preferably provided for adjusting these racks up and down relative to the floor to allow for differences in human stature.

According to another aspect of the present invention it is proposed that a check-out counter system provides the cashier with the option of sitting or standing. When the cashier can alternate between sitting or standing, this changes the major muscle groups being used to maintain the working posture, allowing circulation to flood into fatigued muscles and restore their energy. Thus, according to this aspect of the invention the check-out counter system is provided with a chair which is mounted on a swinging, telescoping arm so that a seated cashier can easily stand to handle bulky or heavy items. The chair can swing out of the way behind the cashier to allow the cashier to move freely. It can then be pulled back into position for seated work. When not in use, the chair can be telscoped into a corner and out of the way.

It has been found that when a seated operator is placed in a posture with his thighs at an angle of 25 to 30 degrees from horizontal rather than horizontal, part of the lumbar curve is restored. In addition, a good lumbar support restores more of the lumbar curve. Restoration of some of the lumbar curve reduces adverse affects of the seated posture. Thus, the chair utilized in the check-out counter system in accordance with this aspect of the invention is preferably designed to place the thighs at an angle of 20 to 30 degrees and is preferably provided with a lumbar support which can be adjusted forward to support the lumbar curve even when the operator is leaning forward. Anthropometric data domonstrates that the adjustment range required for seated operators ranging from 5 feet (1.52m) tall to 6 feet 2 inches (1.88m) tall is slightly less than 2 inches (5.08cm). Provision is preferably made for the chair used in the check-out counter system of this aspect of the invention to be adjustable up and down over a 4 inch (10.16cm) range. Additionally the telescoping arm of the chair is conveniently provided with a brake which allow the cashier to rest comfortably and use the lumbar support correctly when working.

In accordance with yet a further aspect of the invention it is proposed that a check-out counter system should be provided with a keyboard which is mounted on a pedestal at an adjustable desired height and adjustable angle and which is movable from side to side between a position in front of the right shoulder to a position in front of the left shoulder of the cashier facing the keyword to accommodate right-handed and left-handed cashiers.

In accordance with yet another aspect of the present invention a check-out counter system should be designed so as to be capable of maximum productivity under the procedures of "direct bagging" by the cashier or with the use of an additional bagger. When business is light, the cashier may grasp each item in the right hand, record the price, transfer the item to the left hand which then places the item directly in a plastic bag. In this respect, the check-out counter system preferably has provisions for positioning the bag lower than the counter top so that the item can be slid off of the counter and into the bag without any need for lifting up. Movement is across and down. The bag receiving the item is located directly adjacent to the cashier's left side and slightly forward of the cashier's shoulder so that the natural swing of the cashier's left arm deposits the item in the bag. The bag is ideally held open by two arms on a bag pack rack which pass through holes in the bag's handles. These arms hold the bag such that the bottom of the bag rests on a conveyor belt. The conveyor belt should be at such a height that the cashier does not need to bend over to place items in the bag. When the bag is full, the cashier actuates the conveyor belt. Through friction with the bottom of the bag, the conveyor belt pulls the bag off of the supporting arms. As the bag is pulled off the supporting arms, a small deposit of glue on the back of the bag, connecting it to the front surface of the subsequent bag, pulls the subsequent bag open. The conveyor belt may also be placed in a second generally downwardly angled position extending from the countertop of the system for transfer by the cashier of merchandise from the countertop to the conveyor means for conveying to the end of the check-out counter system for bagging by a bagger when business is heavy.

Accordingly, an ergonomically designed check-out counter system in accordance with any of the several aspects of the present invention has a number of features and advantages not present with prior systems. The check-out counter system of the present invention minimizes reach and strength requirements by keeping the load close and centered on the body as much as possible. It avoids repeated lifting of objects at arms length from the body or extending the arms while supporting a load. It avoids repeated bending or leaning forward by the cashier. The check-out counter system provides for alternative standing or sitting by the cashier and adjustability and proper support in the chair. The check-­out counter system locates the cashier and all elements of the system at the correct relative heights so that the worker's arms can hang relaxed and movement of the upper arms can be limited to 60 degrees forward and 45 degrees to the side.

While some of the objects and advantages of this invention have been set forth above, others will become apparent in the detailed description of a preferred embodiment of the invention to follow, when taken in conjunction with the accompanying drawings, in which:

• Figure 1 is an exploded perspective view of the ergonomically designed check-out counter system of this invention;
• Figure 2 is a top plan view of the check-out counter system of Figure 1;
• Figure 3 is a sectional view, taken generally along the line 3-3 of Figure 2;
• Figure 4 is a sectional view, taken generally along the line 4-4 of Figure 3;
• Figure 5 is a sectional view, taken generally along the line 5-5 of Figure 4;
• Figure 6 is a sectional view, taken generally along the line 6-6 of Figure 4;
• Figure 7 is a partial perspective view of the check-out counter system of Figure 1 with components thereof positioned in a direct bagging mode by the cashier;
• Figure 8 is an enlarged perspective detail of a portion of the bagging elements of the check-out counter system as shown in Figure 7;
• Figure 9 is a sectional detail, taken generally along the line 9-9 of Figure 8;
• Figure 10 is a perspective view of the check-out counter system of Figure 1 showing some of the bagging devices positioned in a mode for bagging by an additional bagger; and
• Figure 11 is a sectional detail, taken generally along the line 11-11 of Figure 10.

Referring now to the drawings, there is shown therein a preferred embodiment of an ergonomically designed check-out counter system, for supermarket and merchandising industries, generally indicated at 10, of this invention which includes the improved features discussed broadly above and to be discussed in more detail hereinafter. However, it is to be understood that other embodiments of a check-out counter system could be utilized which incorporate one or more of the improved features of this invention therein.

In Figure 1, there is shown an exploded view of the ergonomically designed check-out counter system 10, of this invention for supermarket and merchandising industries. This check-out counter system 10 is also shown in perspective in Figures 7 and 10 in two different modes of operation, to be discussed more fully below.

The check-out counter system 10 includes an elongate housing 12 having interconnected countertop 13, side wall portions 14, 15 and end wall portions 16, 17 for defining generally the overall shape of the check-out counter system 10. The elongate housing 12 further includes generally an upstream end portion 20 for receiving the merchandise being checked-out, a downstream end portion 21 for bagging the checked-out merchandise and an intermediate portion 22 between the upstream end portion 20 and the downstream end portion 21 for receiving a cashier for checking-out the merchandise. The housing 12 defines an opening 24 in the intermediate portion 22 through at least a portion of the countertop 13 and one of the side wall portions 15 for the positioning of a cashier. The housing 12 further defines an opening 25 in the downstream end portion 21 through a longitudinally extending intermediate area of the countertop 13 for positioning of bagging mechanisms (to be described below).

The check-out counter system 10 includes a floor, shown as three sections 26, 27 and 28 (Figures 1 and 3). However, it is to be understood that one or more of these floor sections 26, 27, 28 could be eliminated and the floor of the environment in which the check-out counter system 10 is placed could be utilized in lieu thereof. The floor section 27 is positioned under the intermediate opening 24 in the housing 12 for receiving the cashier thereon. This floor section 27 includes means for moving this floor section vertically up and down (as shown by the dotted and solid line positions and arrow in Figures 3 and 5) to position the cashier at a desired height in the check-out counter system 10 regardless of the human height or stature of the cashier. This means for moving the floor section 27 up and down may be any suitable mechanical mechanism and, as illustrated schematically in the drawings herein, comprises mechanical jack devices 30, 31 driven by reversible motors 32, 33, respectively. The jack devices 30, 31 are secured between stationary frame member 34 and movable frame member 35 secured to the movable floor section 27. Reversible motors 32, 33 may be operator actuated through any suitable controls (not shown) and a switch panel 37 at the cashier position may be provided for actuating such controls.

The check-out counter system 10 of this invention further includes a movable chair mechanism including a chair 40 positioned in the intermediate opening 24 in the housing 12 above the movable floor section 27 for seating of the cashier. This movable chair mechanism includes means for adjusting the position of the chair 40 vertically relative to the floor section 27 to position the cashier and his legs at desired heights and horizontally from desired positions within the intermediate opening 24 to a position out of the intermediate opening 24 (as shown in solid and dotted line positions and arrows in Figures 2, 3 and 4) to provide the cashier with options at sitting at various positions within the intermediate opening 24 or standing.

This means for adjusting the position of the chair 40 may include any suitable mechanical mechanisms and, as illustrated in the drawings hereof, includes a swinging generally horizontally-extending, telescoping arm device 41 for inward and outward movement and for swinging arcuate movement (Figures 1, 3, 4 and 5). A first generally vertically-extending shaft device 42 is pivotally carried by and extends upwardly from one end of the telescoping arm device 41 and pivotally carries the chair 40 on the upper end thereof. This shaft device 42 may be a two-part telescoping shaft which allows for vertical adjustment up and down of the shaft device 42 and the chair 40 on the upper end thereof. A second generally vertically-extending shaft device 43 has one end thereof suitably secured to the floor section 28 or rests on the floor of the environment and pivotally carries at the upper end thereof the telescoping arm device 41 at an intermediate location thereon. This second shaft device 43 includes a suitable brake device 44 for stopping and holding the telescoping arm device 41 and, thus, the chair 40 at a desired pivoted or swinging arcuate position within the intermediate opening 24. The brake device 44 may be controlled and operated by any suitable control means (not shown) which may be actuated from the switch panel 37 to brake and lock the seat 40 in a desired position for the cashier. The chair 40 may be any suitable ergonomically-designed chair having a good lumbar support and angled seat with suitable adjustments thereof for supporting the lumbar curve of the cashier and placing the thighs at desired angles, as discussed above.

With these adjustment mechanisms, the chair 40 may be adjusted up and down to accommodate a desired position of the cashier and his legs relative to the movable floor section 27 so that the cashier may assume a full seated position or a nearly standing position while in the chair or any positions therebetween. It has been found that an adjustment range of about 4 inches (10.16cm) up and down will accomplish this purpose. Also, the chair 40 may be pivoted around the shaft device 42 so that a seated operator may face in any desired direction within the intermediate opening 24 receiving the cashier or the chair 40 may be swung in an arc about the shaft 43 so that the cashier may assume a desired position within the intermediate opening 24. The chair 40 may also be moved entirely out of the intermediate opening 24 and into a cut-out 46 in the housing 12, when the cashier desires to stand.

For checking out the merchandise in the check-out counter system of this invention, there is provided a keyboard device 50 for manually entering price information, etc. into any desired computer or calculator apparatus by the cashier. This keyboard device 50 includes means for mounting the keyboard on the housing 12 in generally the intermediate portion thereof at a desired adjustable height and for generally horizontal movement between a position in front of the right shoulder of the cashier (Figure 7) to a position in front of the left shoulder of the cashier when facing the keyboard 50 for accommodating both right-handed and left-handed cashiers. This mounting means may include a suitable pedestal 51 extending upwardly to a desired height above the countertop 13 of the housing 12 and a frame 52 having suitable means, such as slide bars 53, therein for movably mounting the keyboard 50 for horizontal back and forth movement. There may also be provided an electronic scanner and scale device 55 for use by the cashier in checking-out merchandise.

The check-out counter system 10 of this invention further includes merchandise bagging mechanisms positioned in the downstream end portion 21 of the housing 12 for bagging of the checked-out merchandise directly by the cashier or by an additional bagger. These bagging mechanisms include a pair of side-by-side longitudinally-­extending conveyor belt devices 60, 61 carried by a movable frame member 62 and driven by suitable motors (not shown) in the direction of the arrows in Figure 1. These conveyor belt devices 60, 61 are positioned in the opening 25 in the downstream end portion 21 for conveying the merchandise away from the cashier and to the end of the check-out counter system 10.

Means are provided for mounting each end of the driven conveyor belt devices 60, 61 for up and down generally vertical movement. The conveyor belt devices 60, 61 may be placed in a first generally horizontal position (Figure 7) lower than the countertop 13 for receiving a bag at the end thereof adjacent to the cashier for direct bagging by the cashier by sliding the merchandise directly off the countertop 13 and into the bag for conveying of the bagged merchandise away to the end of the check-out counter system 10. The conveyor belt devices 60, 61 may also be placed in a second generally downwardly angled position (Figure 10) extending from the countertop 13 for transfer by the cashier of the merchandise from the countertop 13 to the conveyor belt devices 60, 61 for conveying to the end of the check-out counter system 10 for bagging by a bagger.

These mechanisms for mounting the conveyor belt devices 60, 61 for the up and down generally vertical movement may include any suitable mechanical mechanisms and, as illustrated in the drawings herein, include cams 63, 64 of desired profiles positioned under each end and each corner of the conveyor belt devices 60, 61 and movable frame member 62 and cam follower devices 65 suitably connected to each end of the frame member 62 carrying the conveyor belts 60, 61 and operatively engaging the respective cams 63, 64. The cams may be driven for rotation by reversible motors 66 which may be controlled by any suitable control devices (not shown) and actuated from the switch panel 37.

The merchandise bagging mechanisms further include plastic bag pack and rack devices 70 of the general construction currently being marketed by the assignee of the present invention under the trademarks QUICKMATE ® and AUTOMATE ® and as shown in issued U.S. Patent 4,676,378.

These plastic bag pack and rack devices 70 are positioned in the opening 25 in the downstream end portion 21 of the housing 12 at the end thereof adjacent to the cashier and over each of the conveyor belt devices 60, 61 in the first position thereof for direct bagging by the cashier (Figure 7). Plastic bag and rack devices 70 are also positioned on each of the outer ends of the downstream end portion 21 in cut-out portions 71 of the housing 12 for bagging of merchandise by a bagger when the merchandise is conveyed to the end of the check-out counter system 10 by the conveyor belt devices 60, 61 (Figure 10).

The merchandise bagging devices may further include an additional driven longitudinally-extending conveyor belt 72 positioned in the countertop 13 on one side of the opening 25 in the downstream end portion 21 of the housing 12 for transfer by the casher of large merchandise, i.e. beer, soft drinks, etc., which do not specifically require bagging or which may be bagged by a bagger at plastic bag pack and rack devices 70 at the end of the check-out counter system 10. This conveyor belt 72 eliminates the necessity of the cashier to handle this large merchandise.

The plastic bag pack and rack devices 70 include outwardly extending arms 73, suitably attached to the housing 12 or to a self-standing frame forming part of the rack, and pass through holes in the handles of bags 74. The bags 74 are adhesively secured together at one or more spots of adhesive 75 (Figures 8 and 9) so that as a bag 74 filled with merchandise is removed from the arms 73, the subsequent bag 74 in the bag pack will be moved to an open position on the rack arms 73 before the adhesive connection 75 between bags is broken. The rack arms 73, positioned over the conveyor belt devices 60, 61 hold the bags 74 such that the bottom of the bag 74 rests on a respective conveyor belt 60, 61. When the bag is filled with merchandise, the cashier actuates the conveyor belt 60 or 61 and, through friction with the bottom of the bag 74, the conveyor belt pulls the bag full of merchandise off of the rack arms 73 and the connecting adhesive pulls the subsequent bag into open position before the adhesive connection breaks and the filled bag is conveyed to the end of the check-out counter system 10 for removal. The rack arm 73, positioned over the conveyor belt devices 60, 61 are suitably pivotally mounted for pivoting down out of the way when the conveyor belt devices are moved to the second generally downwardly angled position (Figure 10).

The plastic bag pack and rack devices 70 which are positioned at the end of the check-out counter system 10 include means for vertical adjustment of the height thereof to accommodate different height baggers (Figure 11). This height adjustment mechanism may be any suitable mechanical devices and, as shown in Figure 11, includes bars 80 secured in stationary positions on the housing 12 and notches 81 on plates 82 on each side of the rack 83 of the plastic bag and rack device 70.

Thus, the ergonomically design check-out counter system 10 for supermarket and merchandising industries of this invention has been provided with mechanisms to accommodate for differences in human heights, hand and positions of operators and for ease in handling of merchandise to reduce fatigue and injury to the operators while providing maximum productivity under both light and heavy through put requirements.