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
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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
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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
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
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As feedback received from manufacturing professionals
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Ergonomics – Micro Productivity Tool
We had extensively used simple ergonomics assessment tool and achieved
quick, significant productivity / morale improvements
in SME organisations
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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
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• Reduction of work related injuries
• Increase in Productivity / Safety and Quality
• Reduction in absenteeism
• Increase in morale
Benefits of Ergonomics Improvements…
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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
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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
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Industry /Process : Two wheeler Mfg / Assembly
Before Ergonomics Improvement After Ergonomics Improvement
Direct benefit : Fatigue reduction
Indirect benefit : Line stoppage avoided ??
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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
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Industry /Process : Casting manufacturing / Injection moulding
Before Ergonomics Improvement After Ergonomics Improvement
Direct benefit : Fatigue reduction
Indirect benefit : Rejection was under control ???
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Industry / Process : Auto ancillary / Fabrication
Before Ergonomics Improvement After Ergonomics Improvement
Direct benefit : Fatigue reduction & output increase by approx 5 %
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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