"Guarding the Line"
Industrial Engineer
April 2005, pp. 46-49
The author of this article states that Lean manufacturers must be careful to avoid increased worker compensation costs, which can skyrocket if the company does not take ergonomics into consideration: "...lean processes can make jobs highly repetitive while eliminating critical rest time for employees. When ergonomics is not integrated into the process, the repetitive jobs take their toll on employees as stressful postures and high forces are repeated continuously throughout the day." Ergonomics and safety must be included as core values along with waste reduction and value creation.
The following factors are proposed to integrate ergonomics effectively into lean processes:
- Lean prioritization—Ergonomic risk assessments and quality metrics should be incorporated into the value stream mapping process
- Ergonomics training—Basic ergonomic concepts and ergonomic design factors should be included when training team leaders and kaizen team members
- Ergonomic design—Integrating ergonomic design concepts into processes will reduce errors and increase productivity
- CTD (Cumulative Trauma Disorder) risk assessment—This will help design work stations that minimize such injuries
- Stakeholder involvement—Involving employees in the redesign of a process is critical to the success of lean, and this applies to involvement in ergonomic aspects as well
- Quantifying the impact—Tracking and sharing the significant cost savings in productivity, quality, and workers compensation claims will ensure that ergonomics continue to be seen as a priority for management
- Creating a culture for success—Sharing the mission and goals of the Lean process will help create a positive work environment where workplace improvements are expected and accepted
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