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Published on: August 29, 2025
Redesigning assembly stations using ergonomic methods as a lean tool.
M Eswaramoorthi1, Mervyn John, C Arjun Rajagopal
1Department of Mechanical Engineering, PSG College of Technology, Coimbatore, India. moorthi65@yahoo.com
Work (Reading, Mass.)
|February 19, 2010
Summary
This study introduces a lean manufacturing approach to reduce waste in assembly lines. By analyzing operator posture and ergonomic stress, it redesigns workstations to prevent defects and delays.
Area of Science:
- Industrial Engineering
- Ergonomics
- Manufacturing Systems
Background:
- Global economic pressures necessitate cost reduction and quality improvement in manufacturing.
- Lean manufacturing principles focus on continuous waste reduction.
- Improper workplace design can lead to operator burden and waste generation (muri waste).
Purpose of the Study:
- To identify human-system interface areas causing waste in assembly lines.
- To apply a lean perspective to analyze and optimize assembly line operations.
- To reduce muri waste through ergonomic improvements.
Main Methods:
- Utilized Rapid Upper Limb Assessment (RULA) for posture analysis.
- Employed the CATIA V5 platform for detailed ergonomic assessments.
- Measured operator posture parameters and assessed ergonomic stresses.
Main Results:
- Identified specific areas of muri waste generation.
- Quantified ergonomic stresses impacting assembly line efficiency.
- Provided data for targeted process station redesign.
Conclusions:
- Redesigning process stations based on ergonomic analysis effectively prevents waste generation.
- The RULA and CATIA V5 method is effective for assessing and mitigating assembly line waste.
- Implementing lean principles through ergonomic improvements enhances manufacturing competitiveness.
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