Ergonomic Interventions to Prevent Low Back Pain and Boost Productivity in Refrigerator Manufacturing

This thesis examines ergonomic interventions aimed at reducing low back pain and increasing productivity in a refrigerator manufacturing plant in Manizales, Colombia. The focus is on a critical workstation, the "Compressor Island," where improper body mechanics, repetitive bending, and extended working hours contribute to operator discomfort and absenteeism. The study utilized ergonomic assessment tools such as the Rapid Entire Body Assessment (REBA) and Rapid Upper Limb Assessment (RULA) to evaluate risks before and after implementing redesigned carts and shelves. These improvements decreased discomfort by 47% and improved REBA and RULA scores, indicating a substantial reduction in ergonomic risks. Additionally, production efficiency increased, reducing daily task time and enabling more frequent rest breaks. The results show that ergonomic interventions can effectively reduce workplace injuries while enhancing operational productivity, offering significant cost savings for the company.