Workplace ergonomics in lean production environments: A literature review

BACKGROUND: Lean Production Systems (LPS) have become very popular among manufacturing industries, services and large commercial areas. A LPS must develop and consider a set of work features to bring compatibility with workplace ergonomics, namely at a muscular, cognitive and emotional demands level. OBJECTIVE: Identify the most relevant impacts of the adoption of LPS from the ergonomics point of view and summarizes some possible drawbacks for workplace ergonomics due to a flawed application of the LPS. The impacts identified are focused in four dimensions: work pace, intensity and load; worker motivation, satisfaction and stress; autonomy and participation; and health outcome. This paper also discusses the influence that the work organization model has on workplace ergonomics and on the waste elimination previewed by LPS. METHODS: Literature review focused LPS and its impact on occupational ergonomics conditions, as well as on the Health and Safety of workers. The main focus of this research is on LPS implementations in industrial environments and mainly in manufacturing industry workplaces. This is followed by a discussion including the authors’ experience (and previous research). RESULTS: From the reviewed literature it seems that there is no consensus on how Lean principles affect the workplace ergonomics since most authors found positive (advantages) and negative (disadvantages) impacts. CONCLUSIONS: The negative impacts or disadvantages of LPS implementations reviewed may result from the misunderstanding of the Lean principles. Possibly, they also happen due to partial Lean implementations (when only one or two tools were implemented) that may be effective in a specific work context but not suitable to all possible situations as the principles of LPS should not lead, by definition, to any of the reported drawbacks in terms of workplace ergonomics.

Implementation of a lean six sigma project in a production line

Companies from the motorcycles components branch are dealing with a dynamic environment, resulting from the introduction of new products and the increase of market demand. This dynamic environment requires frequent changes in production lines and requires flexibility in the processes, which can cause reductions in the level of quality and productivity. This paper presents a Lean Six Sigma improvement project performed in a production line of the company's machining sector, in order to eliminate losses that cause low productivity, affecting the fulfillment of the production plan and customer satisfaction. The use of Lean methodology following the DMAIC stages allowed analyzing the factors that influence the line productivity loss. The major problems and causes that contribute to a reduction on productivity and that were identified in this study are the lack of standardization in the setup activities and the excessive stoppages for adjustment of the processes that caused an increase of defects. Control charts, Pareto analysis and cause-and-effect diagrams were used to analyze the problem. On the improvement stage, the changes were based on the reconfiguration of the line layout as well as the modernization of the process. Overall, the project justified an investment in new equipment, the defective product units were reduced by 84% and an increase of 29% of line capacity was noticed.

Estudo do trabalho numa empresa de produção de pneus e implementação de ferramentas Lean

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Aplicação de metodologias Lean na secção de tecelagem de uma empresa têxtil

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Implementação de técnicas e princípios de produção lean no processo de pré-confeção de uma indústria de cablagens

Dissertação de mestrado em Engenharia Industrial

Implementação de ferramentas Lean numa empresa de componentes para calçado

Dissertação de mestrado em Engenharia Industrial

Melhoria de processos numa indústria têxtil através da aplicação do paradigma Lean

Dissertação de mestrado em Engenharia Industrial

Desenvolvimento e implementação de ações de melhoria num ambiente Lean Office

Dissertação de mestrado em Engenharia Industrial

Melhoria e normalização de ferramentas de apoio à produção aplicando ferramentas Lean

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Aplicação de princípios e ferramentas Lean numa empresa de produção de cablagens

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Lean Production e Ergonomia: o impacto de estratégias implementadas nas condições de trabalho numa indústria de componentes para automóveis

Dissertação de mestrado em Engenharia Humana

Aplicação de técnicas e procedimentos Lean Production numa empresa da indústria automóvel

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Aplicação de ferramentas Lean e gestão da manutenção numa metalomecânica

Dissertação de mestrado em Engenharia e Gestão da Qualidade

Aplicação de princípios e técnicas de Lean Manufacturing para melhoria do desempenho de linhas de montagem

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Melhoria do desempenho de uma secção de montagem final de uma empresa usando ferramentas Lean Production

Dissertação de mestrado integrado em Engenharia e Gestão Industrial