Application of ergonomics for SME workplace productivity and safety improvements

Application of Ergonomics
on SME workplace
productivity & safety
improvements

www.winningmindssolutions.com
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

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

Ergonomics application
in day to day life

Evolution of Machines..
User Friendly
Fit to work

Evolution of Computers
Big / heavy Small/ light /
User friendly

Evolution of mobile phone
Big / heavy / press Small/ light / cool / easy

Misconception
about
Ergonomics in workplace

• 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

In reality,

Ergonomics – Micro Productivity Tool
We had extensively used simple ergonomics assessment tool and achieved
quick, significant productivity / morale improvements
in SME organisations

Brief about
Ergonomics risk - FATIGUE

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

Work related injuries
Symptoms of work related injuries
Pain
Discomfort
Tingling
Swelling
Numbness
Stiffness
Loss of Strength
Burning Sensation

Impact of Poor Ergonomics ??
FATIGUE

Ergonomics is
scientific study of human work in relation to work.
What is Ergonomics …?

Ergonomics Study focuses on 4 factors …
Optimizing each factors for maximum performance

• Reduction of work related injuries
• Increase in Productivity / Safety and Quality
• Reduction in absenteeism
• Increase in morale
Benefits of Ergonomics Improvements…

• Avoid awkward posture
• Minimize repetitive operation
• Give pause
• Use tool wherever possible
Some of the principles of Ergonomics

Ergonomics application

Is manufacturing shop floor given
importance for Ergonomics Improvements ?

How to Assess Ergonomics Risk Factors or Fatigue in any
Manufacturing process ??

Methodology
****

Ergonomic Assessment Tool
Rapid Entire
Body
Assessment
(REBA)

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

Risk Assessment Checklist
1.Posture
2.Weight and Travel
3.Physical activities / Vibration
4.Environment and Unfavorable work condition

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

Success Case study
Examples

Industry /Process : Two wheeler Mfg / Assembly
Before Ergonomics Improvement After Ergonomics Improvement
Direct benefit : Fatigue reduction
Indirect benefit : Line stoppage avoided ??

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

Industry /Process : Casting manufacturing / Injection moulding
Indirect benefit : Rejection was under control ???

Industry / Process : Auto ancillary / Fabrication
Direct benefit : Fatigue reduction & output increase by approx 5 %

Frequent re-tightening output
1600 no’s / shift
Toggle clamp provided
output 1750 no’s / shift
Industry /Process : Engineering / Press shop

Industry /Process : Two wheeler Mfg / polishing

Flow Improvement -WIP reduction
Industry /Process : Engineering / Assembly

Questions ????

Thank you for your Interest
For more details on productivity improvements, pl mail us to
ganesh@winningmindssolutions.com
mobile : +91 90259 33666
For Business and Life Excellence articles and case studies
pl visit website : www.winningmindssolutions.com

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