Ergonomics interventions to reduce musculoskeletal risk factors in a truck manufacturing plant

• Published in: International journal of industrial ergonomics 2020-01, Vol.75, p.102896, Article 102896
• Main Authors: Zare, Mohsen, Black, Nancy, Sagot, Jean-Claude, Hunault, Gilles, Roquelaure, Yves
• Format: Article
• Language: English
• Subjects: Automotive assembly plant; Engineering; Engineering intervention; Ergonomics; Industrial plants; Intervention; Life Sciences; Manufacturing industry; Musculoskeletal diseases; Musculoskeletal risk factors; Operators; Organizational changing; Physical workload; Risk analysis; Risk assessment; Risk factors; Santé publique et épidémiologie; Stakeholder; Statistics; Workstations
• ISSN: 0169-8141; 1872-8219
• DOI: 10.1016/j.ergon.2019.102896

Ergonomic interventions may potentially reduce MSDs, but the context of industries (barriers, ever-changing situations, dialogue processes) might play a significant role in the success of interventions. This study evaluates the effectiveness of ergonomic interventions including engineering/technical and organizational interventions, and the involvement of the stakeholders in reducing musculoskeletal risk factors/symptoms. A pre-post-test experimental study in non-randomized groups was performed over three years in a sector of a truck assembly plant. The mean age of the operators in the sector for the initial and second assessment time was 42.0 (±7.6) years and 39.0 (±8.7), respectively. The mean length of work experience in the current job was 15.2 (±7.2) years and 13.9 (±7.3) for the initial and second assessment times, respectively. Five engineering ergonomic solutions and organizational interventions were implemented after a comprehensive ergonomic analysis. The organizational interventions consisted mostly of transferring and redistributing the tasks, i.e., ergonomically balancing and redesigning of the workstations. Before performing the interventions, the findings of the ergonomic study were presented at several meetings to encourage the involvement of the stakeholders (including managers, engineers, and operators) in the interventions. This study showed that a combination of ergonomic measures—engineering and organizational interventions—could reduce physical workloads. Musculoskeletal symptoms decreased after interventions although the difference was not significant. •A case of implementing a combination of ergonomic solutions in a real assembly setting.•Workstation redesign and balancing high-risk tasks implemented over the usual production changes and reduced risk factors.•Involving stakeholders in the interventions facilitated the acceptance of most changes.