Ergonomics Applied to Product and Process Design Achieves Immediate, Measurable Cost Savings

Two case studies are used to demonstrate how one company achieved immediate improvements to employee safety and manufacturing profitability by integrating ergonomics assessment and design practices into current product and process improvement efforts. One case study shows how a product design change resulted in a reduction of hand trimming tasks on a molded plastic part, and a cost savings of $0.11 per part. The other case study shows how integration of process performance criteria into an ergonomics assessment method identified a process change which, when implemented, resulted in the elimination of the most stressful materials handling task on the assembly line and a cost savings of $0.10 per part.