Grinding Musculoskeletal Disorder Exposure Reduction Using Ergonomic Methodologies and Space Optimization

Musculoskeletal disorders in the workplace have been seen to affect the employer and employee in significant ways. Companies waste millions of dollars a year on direct and indirect costs of MSD in their companies. Some of those indirect costs include reduced production and quality of product. Employees exposed to MSDs can be affected emotionally and financially as they can lose their job or even their health. That is why reducing exposure to MSDs in the workplace is crucial. The interventions in manufacturing to reduce MSDs can vary depending on the industry. Although there has been research done on different methods that have been seen to be effective in reducing MSDs, the methods are not standardized for all types of work environments. There are some general principles that can be analyzed in order to fit the job situation and potentially reduce MSDs. This paper aims to use ergonomic principles and space optimization to propose potential options to reduce MSDs in the finishing manufacturing process of a company. The job exposure to MSDs was measured through REBA and RULA, assessments indicating an index of severity of exposure. The initial scores were 10 and 7 respectively. The specific company analyzed was found to have exposure to MSDs through the work-cause posture of the employee. Simulations, through SANTOS and SIMIO, were used to predict the potential MSD risk reduction as well as validate the production throughput effect of the potential MSD reduction options. Three main potential solutions were presented. Those MSD reducing potential options consist of ergonomic controls and space optimization principles. This study showed that the implementation of several ergonomic controls, along with space optimization principles, to the worker environment in the finishing manufacturing sector of a company, could reduce MSD exposure in the workplace. The REBA and RULA scores were reduced to scores of 3 and 4 respectively. The simulation of the potential posture after implementing the potential exposed solutions was seen to have only 6% discomfort to the worker. The SIMIO simulation demonstrated a potential increase in production throughput from 72 parts per hour to 143 parts per hour. Although the solutions do provide evidence of potential MSD reduction, they are specific to one company and specific manufacturing stage.