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Application of ergonomics for SME workplace productivity and safety improvements

Organizations are continuously striving for cost efficiency by applying various world-class initiatives across the operational chain. One of the powerful micro productivity tools “Ergonomics” which is not being given much emphasis on improving shop floor productivity and safety aspects in SME organizations. One of the reasons could be a misconception that ergonomics can be applied in product design or ergonomics improvements can be administered by high level scholars or it can be implemented only by large scale organizations etc..But it has been proven in many of the SME organizations with a simplified approach of ergonomics application in shop floor, significant productivity, safety and high level of morale can be achieved in shorter timeline.

This presentation will help you

1)To understand the application of ergonomics on productivity and safety improvements in workplace,
2)To learn simple and powerful methodology to assess the fatigue in workplace and implement RIGHT ergonomics solutions

Application of ergonomics for SME workplace productivity and safety improvements

  1. 1. Application of Ergonomics on SME workplace productivity & safety improvements
  2. 2. Key Learning Objectives…. Application of Ergonomics principles on improving workplace productivity and safety Simple and powerful Ergonomic risk / fatigue assessment Tool Structured methodology to Implement RIGHT solutions to eliminate / reduce fatigue Awareness session to learn
  3. 3. How we structure the contents : Getting familiar with Ergonomics application in day to day life Some misconceptions about Ergonomics in Manufacturing Environments Brief idea about FATIGUE and its impact Introduction to ERGONOMICS and its FACTORS Principles of ERGONOMICS How to identify the FATIGUE risk in any activities Brief about ERGONOMICS ASSESSMENT TOOLS & Methodology CASE STUDY examples on ergonomics application Q&A
  4. 4. Ergonomics application in day to day life
  5. 5.
  6. 6. Evolution of Machines.. User Friendly Fit to work
  7. 7. Evolution of Computers Big / heavy Small/ light / User friendly
  8. 8. Evolution of mobile phone Big / heavy / press Small/ light / cool / easy
  9. 9. Misconception about Ergonomics in workplace
  10. 10. • Ergonomics for products not for process • Ergonomics is for large organizations • Ergonomics can be administered by scholars / consultants • Very difficult to teach to shop floor executives • Ergonomics is for safety and HR related subject As feedback received from manufacturing professionals
  11. 11. In reality,
  12. 12. Ergonomics – Micro Productivity Tool We had extensively used simple ergonomics assessment tool and achieved quick, significant productivity / morale improvements in SME organisations
  13. 13. Brief about Ergonomics risk - FATIGUE
  14. 14. Universal truth is that , Any work is performed by human effort for longer duration will lead into FATIGUE Fatigue can be defined as “tiredness resulting from mental or physical activities for long duration” And From Ergonomics terminology, Fatigue is related as WORK RELATED INJURIES
  15. 15. Work related injuries Symptoms of work related injuries Pain Discomfort Tingling Swelling Numbness Stiffness Loss of Strength Burning Sensation
  16. 16. Impact of Poor Ergonomics ?? FATIGUE
  17. 17. Ergonomics is scientific study of human work in relation to work. What is Ergonomics …?
  18. 18. Ergonomics Study focuses on 4 factors … Optimizing each factors for maximum performance
  19. 19. • Reduction of work related injuries • Increase in Productivity / Safety and Quality • Reduction in absenteeism • Increase in morale Benefits of Ergonomics Improvements…
  20. 20. • Avoid awkward posture • Minimize repetitive operation • Give pause • Use tool wherever possible Some of the principles of Ergonomics
  21. 21. Ergonomics application
  22. 22. Is manufacturing shop floor given importance for Ergonomics Improvements ?
  23. 23. How to Assess Ergonomics Risk Factors or Fatigue in any Manufacturing process ??
  24. 24. Methodology ****
  25. 25. Ergonomic Assessment Tool Rapid Entire Body Assessment (REBA)
  26. 26. Methodology Operation Description : Posture 1 Upper body bent 2 Sitting position 3 Arms outstretched (away from body) 4 Body front side bent 5 Body back side bent 1 Load carrying by both hands 2 Pull or push the load 3 Bending and Picking 4 Carrying the load on shoulder 1 Manual pressing/pushing, pressing in/pulling through, shaking etc. 2 Manual work with hand tools (hammer, caulker, chisel, cutter, etc.) 3 Manual repetitive tightening for Screw, Bolt, Nut and etc. 4 Manual repetitive cleaning, Brushing, Burr removing 1 Temperature level too high / too low 2 Noise level too high 3 Visual obstruction / Physical obstruction Total Score Workplace -Ergonomics Risk Assessment Handling loads Physical activities Environment &Layout Examples Element Description: Observername : Date of observation: Simplified fatigue assessment checklist
  27. 27. Risk Assessment Checklist 1.Posture 2.Weight and Travel 3.Physical activities / Vibration 4.Environment and Unfavorable work condition
  28. 28. Go to workplace & Observe….
  29. 29. Operation : Nut Tightening # Operation Element description Ergonomic Risk score** Ergonomic Risk description Improvement Opportunity 1 Nut tightening Pick rim assy from trolley 1 turn and pick wheel from trolley (Posture) Relayout trolley position Hold rim assy manually 2 posture (bend ),vibration Increase height of the machine by using table in line with eye level Tighten the nut ( repetitive-36 no's) 4 Posture ,( bend), repetitive ,restricted visibility , vibration avoid bending by increasing height of fixture Load rim assy in trolley 1 turn and load in trolley (Posture) automated indexing avoid holding with fixture Relayout of trolley position Example Element description / Risk Assessment / Opportunity Identification ** using simplified fatigue assessment checklist
  30. 30. Success Case study Examples
  31. 31. Industry /Process : Two wheeler Mfg / Assembly Before Ergonomics Improvement After Ergonomics Improvement Direct benefit : Fatigue reduction Indirect benefit : Line stoppage avoided ??
  32. 32. Picking and Placing time improvement : 24 % Stripper storage in wooden box Stripper storage in dedicated stand Industry /Process : Engineering / Press Before Ergonomics Improvement After Ergonomics Improvement
  33. 33. Industry /Process : Casting manufacturing / Injection moulding Before Ergonomics Improvement After Ergonomics Improvement Direct benefit : Fatigue reduction Indirect benefit : Rejection was under control ???
  34. 34. Industry / Process : Auto ancillary / Fabrication Before Ergonomics Improvement After Ergonomics Improvement Direct benefit : Fatigue reduction & output increase by approx 5 %
  35. 35. Frequent re-tightening output 1600 no’s / shift Toggle clamp provided output 1750 no’s / shift Industry /Process : Engineering / Press shop Before Ergonomics Improvement After Ergonomics Improvement
  36. 36. Industry /Process : Two wheeler Mfg / polishing Before Ergonomics Improvement After Ergonomics Improvement Direct benefit : Fatigue reduction
  37. 37. Flow Improvement -WIP reduction Industry /Process : Engineering / Assembly Before Ergonomics Improvement After Ergonomics Improvement
  38. 38. Questions ????
  39. 39. Thank you for your Interest For more details on productivity improvements, pl mail us to mobile : +91 90259 33666 For Business and Life Excellence articles and case studies pl visit website :