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A learning curve-based method to implement multifunctional work teams in the Brazilian footwear sector
L B de M Guimarães1, M J Anzanello, J S Renner
1Department of Industrial Engineering, Federal University of Rio Grande do Sul (UFRGS), Av. Osvaldo Aranha, 99 - 5° andar, Porto Alegre - CEP 90.035-190, Rio Grande do Sul, Brazil.
Implementing multifunctional work teams in footwear manufacturing significantly reduced accidents and improved output. This approach enhances worker training and resources, leading to better performance and fewer injuries.
Area of Science:
- Industrial Engineering
- Ergonomics
- Organizational Psychology
Background:
- Traditional Taylor/Ford systems in footwear manufacturing often lead to repetitive strain and limited worker development.
- The need for adaptable and healthier work environments is critical in manufacturing settings.
Purpose of the Study:
- To introduce a novel framework for implementing multifunctional work teams in a traditional footwear company.
- To assess the impact of task rotation and macroergonomic principles on worker performance and well-being.
Main Methods:
- Learning Curve (LC) modeling was employed to evaluate the effect of task complexity rotation on worker learning and performance.
- Macroergonomic Work Analysis (MA) was utilized to integrate multifunctional principles, enhancing worker training and resource allocation.
Main Results:
- A pilot implementation with 100 workers demonstrated an 80% reduction in work-related accidents and a 45.65% decrease in absenteeism.
- Work-related musculoskeletal disorders (WMSD), medical consultations, and turnover were eliminated.
- Output rate increased by an average of 3%, while rework and spoilage rates decreased by 85% and 69%, respectively.
Conclusions:
- Multifunctional work teams, guided by LC modeling and MA, offer a viable and beneficial alternative to Taylor/Ford systems in footwear manufacturing.
- The proposed framework significantly improves worker safety, reduces operational costs, and enhances overall productivity.
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