The relationship between physical workload and quality within line-based assembly

Abstract Reducing costs and improvement of product quality are considered important to ensure productivity within a company. Quality deviations during production processes and ergonomics have previously shown to be associated. This study explored the relationship between physical workload and real (found during production processes) and potential (need of extra time and assistance to complete tasks) quality deviations in a line-based assembly plant. The physical workload on and the work rotation between 52 workstations were assessed. As the outcome, real and potential quality deviations were studied during 10 weeks. Results show that workstations with higher physical workload had significantly more real deviations compared to lower workload stations. Static work posture had significantly more potential deviations. Rotation between high and low workload was related to fewer quality deviations compared to rotation between only high workload stations. In conclusion, physical ergonomics seems to be related to real and potential quality deviation within line-based assembly. Practitioner Summary: To ensure good productivity in manufacturing industries, it is important to reduce costs and improve product quality. This study shows that high physical workload is associated with quality deviations and need of extra time and assistance to complete tasks within line-based assembly, which can be financially expensive for a company.

[1]  Anasua Bhattacharya,et al.  Costs of occupational musculoskeletal disorders (MSDs) in the United States , 2014 .

[2]  L. Punnett,et al.  Work-related musculoskeletal disorders: the epidemiologic evidence and the debate. , 2004, Journal of electromyography and kinesiology : official journal of the International Society of Electrophysiological Kinesiology.

[3]  Colin G. Drury,et al.  Ergonomics and quality in paced assembly lines , 2001 .

[4]  J. Côté.  A critical review on physical factors and functional characteristics that may explain a sex/gender difference in work-related neck/shoulder disorders , 2012, Ergonomics.

[5]  D B Chaffin,et al.  Shoulder disorders and postural stress in automobile assembly work. , 2000, Scandinavian journal of work, environment & health.

[6]  W M Keyserling,et al.  Workplace risk factors and occupational musculoskeletal disorders, Part 1: A review of biomechanical and psychophysical research on risk factors associated with low-back pain. , 2000, AIHAJ : a journal for the science of occupational and environmental health and safety.

[7]  Monique H W Frings-Dresen,et al.  Effects of job rotation on musculoskeletal complaints and related work exposures: a systematic literature review , 2015, Ergonomics.

[8]  Ann-Christine Falck,et al.  Assembly failures and action cost in relation to complexity level and assembly ergonomics in manual assembly (part 2) , 2014 .

[9]  Peregrin Spielholz,et al.  Estimating the effectiveness of ergonomics interventions through case studies: implications for predictive cost-benefit analysis. , 2008, Journal of safety research.

[10]  Leanna M. Horton,et al.  Effects of rotation frequency and task order on localised muscle fatigue and performance during repetitive static shoulder exertions , 2012, Ergonomics.

[11]  Ralph Bruder,et al.  The charge of ergonomics--a model according to the influence of ergonomic workplace design for economical and efficient indicators of the automotive industry. , 2012, Work.

[12]  E. Vieira,et al.  Risk factors for work-related musculoskeletal disorders: A systematic review of recent longitudinal studies. , 2009, American journal of industrial medicine.

[13]  S. Hunter,et al.  Sex differences in human fatigability: mechanisms and insight to physiological responses , 2014, Acta physiologica.

[14]  Ann-Christine Falck,et al.  The impact of poor assembly ergonomics on product quality: A cost–benefit analysis in car manufacturing , 2010 .

[15]  Paul H.P. Yeow,et al.  Proving external validity of ergonomics and quality relationship through review of real-world case studies , 2011 .

[16]  Mervyn John,et al.  Redesigning assembly stations using ergonomic methods as a lean tool. , 2010, Work.

[17]  Ann-Christine Falck,et al.  The impact of poor assembly ergonomics on product quality: A cost-benefit analysis in car manufacturing: Poor Assembly Ergonomics and Product Quality , 2010 .

[18]  J Eklund,et al.  Ergonomics, quality and continuous improvement--conceptual and empirical relationships in an industrial context. , 1997, Ergonomics.

[19]  Pascal Madeleine,et al.  Gender effects on the coordination of subdivisions of the trapezius muscle during a repetitive box-folding task , 2012, European Journal of Applied Physiology.

[20]  J. Caro,et al.  A systematic review of low back pain cost of illness studies in the United States and internationally. , 2008, The spine journal : official journal of the North American Spine Society.

[21]  W M Keyserling,et al.  Workplace risk factors and occupational musculoskeletal disorders, Part 2: A review of biomechanical and psychophysical research on risk factors associated with upper extremity disorders. , 2000, AIHAJ : a journal for the science of occupational and environmental health and safety.

[22]  Martin Schmauder,et al.  Good ergonomics and team diversity reduce absenteeism and errors in car manufacturing , 2014, Ergonomics.

[23]  John D. Barrett,et al.  Quality From Customer Needs to Customer Satisfaction , 2004, Technometrics.

[24]  J A Eklund,et al.  Relationships between ergonomics and quality in assembly work. , 1995, Applied ergonomics.

[25]  P Madeleine,et al.  On functional motor adaptations: from the quantification of motor strategies to the prevention of musculoskeletal disorders in the neck–shoulder region , 2010, Acta physiologica.