PRODUCTIVITY IMPROVEMENT
AT A MANUFACTURING WORKSTATION THROUGH
APPLICATION OF ERGONOMIC PRINCIPLES
Sushmita Tatineni, St. Cloud State University
Alekhya Marripudi, St. Cloud State University
Hiral A. Shah, Ph.D., CEI, EMCP, CAPM, St. Cloud State University
Abstract
An appliance manufacturer reported lack of
productivity at a consumer freezer assembly line. The
procedure of connecting tube while fixing the screws
and turning the shell of the product on a repeated basis
required continuous body movement along with high
pressure to be applied by the operator. The goal of this
project was to observe and evaluate instances of human
machine interface which may result into significant
stress on the shoulder and lower back and thereby
improve the productivity of the workstation. Time
study and ergonomic evaluation was conducted to find
the frequency of each freezer being turned and to
measure stress. Few alternative approaches were
designed and recommended to the company. One of the
suggestions required addition of an operator to lift the
shell while another approach recommended application
of job rotation principle. Results of this project and a
discussion of a cost-effective approach to solve the
problem are presented in this paper.
Key words: Ergonomics, manufacturing, job rotation,
productivity, case study.
Introduction
Johnson and Konz (1999) stated a working definition
from Raymond Corporation and described ergonomics
as the study of work organization and the
human/machine interface in particular. Not to be
confused with mere appearance, ergonomic design is a
science devoted to helping the machine operator to be
more productive by allowing him/her to operate more
efficiently, comfortably, and safely.
Ergonomics plays an important role in every aspect.
Many principles have to be taken into account in order
to follow the appropriate conditions. Regular body
movements tend to provide physical exercise to the
human body, but there are few movements or postures
that results into side effects.
The application of ergonomics is most suitable in
the industrial manufacturing environment. With
economic constraints of increased productivity,
increased flexibility, and decreased unit production
cost, ergonomics is becoming increasingly important in
the manufacturing environment. Due to the
tremendous amount of effort the operator exerts doing
her job, there is a significant likelihood of back or
shoulder injury. Hence, certain precautionary measures
have to be taken into consideration in order to keep the
operator injury free.
To keep the operator injury free is a major goal of
ergonomics. To achieve this goal, few restrictions can
be taken into consideration. These include but are not
limited to work station layout, maintenance policies,
safety factors, and failure locations.
Stress Measurement Techniques
There are certain measures to assess various human
movements and it is possible to estimate the strain and
stress levels in a particular area. Xerox Corporation
(n.d.) implies that more the movement more is the
stress exerted on the area. The stress level exceeds with
greater number of movements and depends on the
frequency of the movement of the fingers, arms, and
hands. Different companies follow different methods
to assess different movements. Brough (n.d.) designed
a pictorial format for rating the movement and
described the levels of stress as shown in Exhibit 1.
Here the first stress exposed area is the arm. A scale is
given to the most number of movements. If arm seldom
moves the rating can be given as zero and if the arm
movement is for ten to fifteen times in a minute then
the scale is marked to two. If arm is moved sixteen to
twenty times in a minute the scale indicates four. For
twenty-one to thirty movements in a minute the scales
shows a rating of six and scales results in 8 if the
movements of the arm is constant. But the reading up
to four is moderate and anything at six is a high force.
Thus, the arm is studied at different stress levels.
Wrist twist is second element to give a scaling. If
there is no twisting then it can be given zero. If it is
five to ten times per minute scaling is marked to two.
For eleven to fifteen times a minute scaling can be
shown at a rating of four. Six can be given to sixteen
to twenty times movement per minute. If there is a
constant movement for the wrist of the operator then
the rating can be shown as eight. Moderate rating is
four but high force is indicated as six. Just as the wrist
twist, there is also scaling derived for wrist movement.
For a seldom movement it is marked as zero. If the
wrist moves for ten to twenty times per minute then a
scaling of two is awarded. Twenty-one to thirty times
in minutes indicates a scale of four. Six is given to
thirty-one to forty times in minute. If there is a constant
movement of the wrist then the scale indicates eight.
Any moderate movement of wrist is up to four and
high force is six.
Finger movements are always necessary in a
physical activity. Fingers are also often exposed to
different stress levels. If fingers seldom move then
rating can be shown as zero. If fingers are moving
fifteen to twenty-five times per minute then rating is
indicated as two. Twenty six to forty times movement
in a minute indicates a scale of four. Fingers moving
from forty-one to sixty times in a minute result in a rate
of six. If there is a constant movement of the finger
then rating is implied as eight. Fingers moving
moderately can be given a rating for four and finger
movements with higher force are given as six.
Head and neck movements can also be rated
according to the angles bent. If the head is straight or if
the head often moves then rating can be zero. If the
head and neck is bent between angles five and ten
degrees then a rating of two is awarded. If the bent
angle of head is between eleven to twenty degrees then
the rating is four. If the head and neck bent angles are
between twenty-one to thirty degrees then rating is
given as six. If head and neck is bent more than thirty
degrees then rating is given as eight. Rating is eight
even if the head is bent backwards.
Back positions are also the most important factors
to be taken into account while assessing the stress
levels. A normal posture is given a scale of zero. If
the bent in back position is zero to ten degrees then the
rating is two. If the bent is between eleven to fifteen
degrees then the scale is marked as four. Bent between
sixteen to twenty degrees is six. Bent above twenty
degrees is marked as eight. If the back position is
changed often then the scale can be kept at zero.
Forward movement of the elbow is zero if it is a
little movement. But the scale increases as the elbow
moves forward. If the elbow is at an angle of forty to
sixty degrees to the body then rating of two, four, and
six are given. If the elbow movement is closer to ninety
degrees to the human body or if the elbow is
perpendicular to the body then the scale can be marked
at eight. Similarly the sideways are also given a rating.
If the elbow moves parallel to the body at an angle
between thirty to sixty degrees then the rating can be
awarded as zero, two, four, and six respectively. If the
elbow moves away from the body and is almost
straight to the shoulder level then the rating is eight.
Forearm is other part of the arm which is rated at zero,
two, and four if the arm movement is just above normal
movement. If the arm is moving with a light force and
closer to the chest part of the operator’s body then the
rating is six and if the forearm is moving with same
light force but closer to the lower part of the body then
the rating is six. If the forearm is moving with light
force but almost closer to the face of the operator then
the rating is given as eight and if the forearm is moved
closer to the knee then the rating is eight. Similarly, if
the forearm is moving with heavier weight and is closer
to the body then the rating is indicated as zero, two,
four, and six. The rating is eight if a heavy force is
exerted on the forearm and the position of the arm is in
parallel to the chest.
If the wrist of the operator is straight then rating is
zero. If wrist is bent ten percent of time then rating is
two. If the bent is ten to twenty percent of the time
then rating is four and it is six if the bent is between
twenty to thirty percent of the time. If the bent is more
than thirty percent of the time then rating is indicated
as eight. Force and grip are other major concerns for
rating the operator’s force in job. If the power applied
is between zero to four ounces then the rating can be
zero. If the power is between five to nine ounces then
scaling is zero and if there is ten to sixteen ounces of
power then also scaling can be zero. But power more
than sixteen ounces is considered or awarded as two.
Just like power, pinch is also given a scale. If the
pinch is between zero to four ounces then the rating is
zero. If the pinch rate is between five to nine ounces
then scale is shown to four. Pinch between ten to
sixteen ounces is rated at six. If the pinch rate is above
sixteen ounces then the rating is given at eight. Force
grip to open an object is also given a rating such as
zero if the force grip to open is between zero to four
ounces. If the force grip to open is between five to
nine ounces then the rating is two, between ten to
sixteen ounces is six, and if the force grip to open is
above sixteen ounces then rating is given at a scale of
eight. Additional two points are awards to all these
activities if the operator is wearing gloves and
performing the desired action.
Contact is the other part of exposure to stress. If
there is little or no contact then the rating is zero and if
there is a probability of contact then the rating is
awarded as two. If there is a contact or calluses then
the rating can be at four. If there is an abrasion then
the rating is six and if there is a swelling or numbness
scale can reach eight. If there are no vibrations then
rating is at zero and if there are mild vibrations then
rating can be two. For occasional vibrations rating can
be marked as four. But for frequent vibrations rating is
given as six and for constant vibrations rating is set at
eight.
Finally, depending on all these factors and
observation made on the operation of the operator, a
rating can be given to the opinion. If the operator’s
work or job seems to be very easy then opinion can be
rated at zero, if the operator’s operation seems or looks
easy then rating is given as two. If the operator’s job is
moderate then the rating is four. If the operator’s
activity is hard then rating is given as six and if the
operator’s job is very difficult then the rating is given
as eight.
Distance is a powerful as well as effective
protective technique. Making distances between
operators and machinery or equipment reduces the
chances of injury. Work measurement also helps in
analyzing the capability of the work and can be
improved. Safety tags and messages can help in
creating awareness among operators. Work
instructions play a primary role for ergonomics.
Defining the work and steps helps the operator to take
necessary precautions.
Therefore, ergonomics is an integral factor in the
designing of process and jobs. Physical activities such
as walking, lifting, sitting, exerting force and other
musculoskeletal jobs are to be given high priority in an
industry to reduce physical stress for the operators.
Interaction between the machinery and people should
be clearly described and proper training should be
given which helps the industry to keep operator safe.
Follow up and verification is a continuous process
to keep on with the principles of ergonomics. This will
reduce the potential hazards.
Problem Description
Manufacturing freezers is one of the industries that
require more number of operators or worker during the
production stage. This study includes the state where
the operators need to exert physical force during the
operation. Assembly line includes different procedures
while the freezer is being assembled. There is one
particular point where the operator has to flip the
freezer before proceeding through the line. This
appliance manufacturing company includes two
different assembly lines manufacturing various models
with different size freezers. The first line named as
Line 1 produces single type of freezer about 12 cubic
feet and weighs 40-50 pounds. The line speed is 26.03
seconds and therefore, the operator has to flip a freezer
for every 25 seconds. Since the shift is for 8 hours with
20 minutes break the total operating time for the shift is
27,600 seconds. The line runs 1060 units in a shift.
Operator has to flip all the 1060 units throughout the
shift. This operation is carried by a female operator.
The second line or Line 2 produces various types
of freezer and usually runs high end models with
different features and with sizes varying from 17 cubic
feet to 21 cubic feet. This line makes commercial
models that require higher capacity for compressor.
There are models that include fans and capacitors due
to which the shells weigh 70-80 pounds. Other models
include higher evaporators and double heaters. Thus,
the shell weight increases. This line runs at a speed of
25.67 seconds and the operators lifts or flips each shell
every 25 seconds. The production time for this line is
27,600 seconds and 1075 units are being produced in
each shift. This operation is carried by a male
operator.
Flipping the freezer involves different postures. An
operator has to push the freezer and then lift it while
flipping and placing it back on the line. While pushing
force is maintained by both the hands and also the
shoulders. While lifting, lower body is involved to
balance the posture. At this point the weight that is
controlled by the hands of the operator is put on the
lower back of the body. The major goal of our study is
bedded on this point where the operator has a chance of
being affected. This can occur immediately or during a
long run. When there is a force on the human body
involving high weights, there is a possibility of disc
dislocation. This is also called as disc prolapse. The
back bone undergoes pressure due to which the
vertebrae has high rate of dislocation. This results into
ill-effects for the operator.
Data Collection and Analysis
Time studies were conducted and each action was
defined using a predetermined code. Since the line
speed was 25.03 seconds and 25.67 seconds
respectively, the operators on both lines 1 and 2 have to
flip a shell for every 25 seconds. The pressure exerted
on the shoulders and lower back of the operator
indicates certain hazards for the operators.
As a part of data collection an interview was
conducted with a general physician. The medical
officer’s experience indicated that females are exposed
to more musculoskeletal injuries during 45-50 years of
age and men during their 50s and it takes longer time to
recover as these are bone related issues.
The operator currently working for Line 1 was
aged around 43, indicating that she either prone to any
musculoskeletal injury while currently working on the
line or in the long run. For Line 2 there was a male
operator working but this operator lifts or flips shells of
different sizes. There are heavier shells and operator
has to put some more effort or pressure to flip the
freezer on the line.
Ness Consulting, Inc. (n.d.) mentioned that
depending on the scaling factor the operators are given
a rating for the job or activities that they perform. A
chart was made for the movements of the wrist, arm,
grasping force, weight lifted and position of the
operator during operation, frequency of the back
angles, twisting of the wrist and finally the opinion of
the operator and recommendations for this. During this
operation, the weight of the shell was above fifty
pounds due to which rating was given as eight. The
back position angle was between thirty to forty degrees
and the rating for this was given as six. Since the
operator was lifting a heavy shell, the grasping rating
was given as eight. There were no frequent
movements for twisting and hence the scaling was
zero. Position was awarded at a rate of six. From all
these ratings the opinion given for this was eight
because the job of flipping shells for one continuous
shift was difficult for the operator to keep this job
constant. Operator’s opinion for this job was also
given importance. In this case, the operator showed a
dislike towards lifting the shell. Therefore, few
alternative solutions were designed and recommended
to the company for the safety of the operators.
Possible Solutions to the Problem
Approach A or the first solution was to have additional
operator to help lifting the shell. Due to the additional
help, the current operator has to put little effort to push
or lift the shell. Therefore, it can reduce the stress on
the operator’s body. Moreover, it can also keep the
freezer safe as there is another operator on the opposite
side to hold the freezer.
Approach B or the second solution to this problem
was to switch the operators. Since there are 3 breaks
during each shift, operator who flips the freezer till the
first break can go to an easier job after the break. This
provision of rest can also reduce the strain on the
operator’s body. The next operator can work till the
second break and can go for an easier job after that.
With approach B, it is possible to reduce the stress
exerted and it can result in saving cost for the company
by eliminating the need for an additional operator.
Moreover, the second operator can pass on this work to
the final operator, thereby; each operator gets lesser
time to flip the freezer.
Conclusion
In this study operators working with heavy shell in a
manufacturing industry were exposed to stress levels
due to the manual operation of flipping the freezer.
Due to the continuous motion and repeated activity it
was understood that ergonomically operators were
undergoing pressure and exceeding the safety levels.
The goal of this project was to observe the operator,
understand the postures and stress exposed area, and
look for other alternatives that can reduce this strain on
the operator.
Two solutions were determined to overcome the
problem. Approach B was to employ an additional
operator to complete the task and split the work
between two operators. Through further evaluation, it
was concluded that applying approach B would add
cost of bringing in a new operator. Besides, the
company would be required to keep tracking the
operators and train them occasionally on their jobs to
protect their safety. Approach A was more feasible
since the work could be carried on with the same
number of operators. Therefore, it will not cost the
company to bring in a new operator. It was concluded
that operators will be more satisfied as they rotate their
job by working less time on heavy freezer and get a
different job during breaks.
The company has implemented approach A on an
experimental basis and has noticed that operators now
find their job to be easy and they enjoy working on
different tasks. This has resulted in employee
satisfaction and safety. Besides, the stress level has
decreased as the operator flips the shell less number of
times and for less number of hours due to the job
rotation.
References
Johnson, Steven, and Stephan A. Konz, Work Design:
Industrial Ergonomics, fifth edition, Holcomb
Hathaway Publishing (1999).
Xerox Corporation Manual, Application of Ergonomics
Principles (n.d).
Neese Consulting, Inc. Ergonomics: Setting the Gold
Standards (n.d.)
Brough William R., Certified Professional Ergonomist,
Body Basic Evaluation Sheet (n.d).
About the Authors
Alekhya Marripudi received her Bachelor’s of
Technology in Computer Science and Engineering
from Jawaharlal Nehru Technological University,
India. She is currently pursuing her Masters in
Engineering Management at St.Cloud State University,
St.Cloud, MN. She will be graduating in December
2010. She is currently working as an intern at
Electrolux in St.Cloud, MN.
Sushmita Tatineni received her Bachelor’s of
Technology in Computer Science and Information
Technology from Jawaharlal Nehru Technological
University, India. She is currently pursuing her
Masters in Engineering Management at St.Cloud State
University, St.Cloud, MN. She will be graduating in
May 2010.
Hiral A. Shah is an Assistant Professor in the
Mechanical and Manufacturing Department at St.
Cloud State University. She received her Ph.D. in
Technology with a concentration in Engineering
Management from Eastern Michigan University. She
holds an M.S. degree in Engineering Management from
Eastern Michigan University and B.S. degree in
Mechanical Engineering from Maharaja Sayajirao
University of Baroda, India. She is a Certified
Enterprise Integrator (CEI), Engineering Management
Certification Professional (EMCP), and Certified
Associate in Project Management (CAPM). Her
research interest is in the area of online teaching,
curriculum and certification exam development, and
lean manufacturing.

Exhibit 1. Body Basic Evaluation