This document summarizes an ergonomics project report. It defines ergonomics as the study of natural laws governing human work. The report discusses how ergonomics can enhance safety, reduce fatigue and stress, and improve employee morale and quality. It analyzes specific tasks at a car manufacturing plant and identifies ergonomic issues like repetitive motions, forceful exertions, and awkward postures. The report describes improvements made like adjustable workstations and material reorganization. It evaluates tasks using the REBA method to assess risk levels. Overall, the report shows how ergonomic changes can benefit workers through reduced injuries, illness, and costs while improving productivity.

1. A project report by : Shibam Sarbswa
Under the Mentorship of : Akash Joshi
Deputy Manager
Maruti Suzuki India Limited

2. Ergonomics
Ergonomics - Ergonomics means the natural laws governing human work
“ergon” = work
“nomos” = natural laws

3. ERGONOMICS

4. Why Ergonomics ?
Enhancing the certain human values including improved
safety, reduced fatigue & reduced stress.
Less cases of unplanned absenteeism.
Better employee morale leading to quality
improvement.
Enhancing the efficiency and effectiveness with which
the work and other activities are carried out.

5. ERGONOMICS
the task
(job content &
context)
the
organization
the
environment
the
tool
the
workstation

6. Major organizations involved
The Institute of Ergonomics and Human Factors
International Ergonomics Association (IEA)
National Institute of Industrial Engineering (NITIE)
Operational Health & Safety Advisory services
(OHSAS), British
National Institute for Occupational Safety & Health
(NIOSH), USA

7. Dispensary study
50 to 60 cases of muscular back pain is reported every
month in our Dispensary.

8. Ergonomics Improvement
Before
After
Platform
4L
6L
4L
5L
6L
4R
•
5L
5R
6R
4R
5R
6R
•
The operator had to cover a larger distance to
pick up door glass for YE3
Benefits
6 Steps per Cycle
Saved.
A platform has been provided in between with the
door glasses of YE3 & YR9 placed on opposite sides
now

9. Steering Column fitment

10. Before:
The operator has to
Twist
Stretch &
Bend
Total Cycles/Shift – 400
Thus the operator has to repeat the
Bend, twist, stretch activity 400 times
a day.

11. After:
No Twisting
No stretching
Lesser Bending
Ergonomic evaluation of production lines is
needed to identify such high fatigue areas.

12. Case Study - Rear Axle(K10)
Weight = 9kg
Number of cars per shift = 350 (8 hour shift)
Number of lifts per minute = 350/(8 x 60)=0.729

13. Before
After

14. Initial Condition
Final Condition
5
5
20
130
41
40

15. Posture Analysis
Body Postures
Neck
Position
Trunk
Position
Legs
Position
Upper Arm
Position
Lower Arm
Position
Wrist
Position

16. REBA
REBA-Rapid Entire Body Assessment
REBA Employee Assessment Worksheet
is used for calculating type of risk.

17. REBA Sheet helps in Identifying the Risk

18. Types of Risk
• Score=1
Low risk
•Score=2or3
•change may be needed
Medium
Risk
•Score=4 to 7
•further investigation, change soon
High Risk
•Score=8 to 10
•investigate and implement change
Very High
Risk
•Score=11+
•implement
change

19. Fatigue prone activity using REBA
The assessment in case of REBA is done using the
REBA sheet where we observe the posture and give
the scores.
Based on the final score, the activity can be
categorized.

20. Risk Factor: ERGONOMICS
Forceful exertion

21. Risk Factor: ERGONOMICS
Repetitive movement

22. Risk Factor: ERGONOMICS
Extreme range of motion

23. Risk Factor: ERGONOMICS
Awkward posture

24. Utilities
One Area one Improvement Drive
Ergonomic risk assessment of stations
Operator step reduction Activities
Installation of synchronic trolleys
Operator cross movement reduction
Sequence supply of components
Material Location Improvement
Work balancing.

25. Advantages of Ergonomics
Installation of synchronic trolleys
Operator cross movement reduction
Sequence supply of components
Material Location Improvement
Work balancing

26. Benefits to the workers
Enhanced worker motivation and job satisfaction
Added problem-solving capacity
Greater acceptance of change
Greater knowledge of work and organization
Reduces injuries and illnesses
Improves employee morale and productivity
Reduces workers’ compensation costs

27. “I still need more healthy rest in order to
work at my best. My health is the main
capital I have and I want to administer it
intelligently.”
- Ernest Hemmingway
Nobel Prize winner for literature