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Ergonomics for Manufacturing

Manufacturing environments present unique ergonomic challenges that can increase injury risk, reduce productivity, and impact workforce sustainability. Browse the resources below for practical guidance, tools, and insights to help manufacturing organizations identify risk factors, improve job design, and support safer, more efficient operations.

Impact

25% Increase
in Productivity

At an inbound fulfilment center, employees hand-scanned garments into stocking locations. The client was paid for every piece scanned in. As a result of an ergonomics assessment, the scanning operation was optimized, and the productivity of the ten employees in the area increased by over 25%. Hand-wrist posture was also improved from a bent posture toward the small finger to a straight posture.

3,300 hrs/year
Savings

In a manual trimming operation in a commercial school photography facility, employees made extended reaches to a manual paper cutter.  The safety latch on the cutter was not engaged because it required an even further extended reach. By investing $1,000 in a mechanical trimmer, the company reduced its ergonomics risks, and the productivity gains equated to over 3,300 hours per year. 

25% Reduced
Processing Time

At a facility assembling components for aerospace fuel systems, employees adopted awkward shoulder, arm, and neck postures to tighten a fitting on a canister. After reorienting the canister at an angle, the assembly process time for this component was reduced by 25%.

95% Reduction
in Claims Cost

After a comprehensive effort that included onsite assessments, employee training, and engineering workshops focused on ergonomics design and process improvements, this major pharmaceutical company reduced its ergonomics-related claim costs by 95%.

Over 25%
Productivity Increase

At a major tire manufacturing facility, employees were tasked with repackaging the “steel belts” that go into tires from Gaylord boxes to spring-loaded drums.  By elevating the boxes and shifting the drums three feet away, employee productivity increased by over 25% due to improved work postures.

Alleviating
Risk

At a facility manufacturing arc-rated rubber PPE, a guillotine press was found to have inadequate guarding. While the operator was protected, anyone approaching the machine from the rear could gain access to the guillotine and suffer a catastrophic injury. The machine was retrofitted with appropriate guarding to prevent unauthorized/inadvertent access, alleviating risk.

Articles

What’s On Your Table?

We all like to eat a good meal, but many people don’t always understand, or appreciate the efforts that are required of […]

Video Resources

Ergo Baby Steps

Self-inflicted Risk Factors

Ergo Stretching

Right Tools

Keep it Simple

Extreme Reaches

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