Ergonomic Design and Analysis of Workstations in Manufacturing Industries for Enhanced Safety and Productivity
Keywords:
Ergonomics, Six Sigma, DMAIC, Prductivity, Ergonomic Risk Assessment, Manufacturing system, Quality ImprovementAbstract
A key strategy for achieving long-term productivity in modern industrial systems is combining ergonomics with quality improvement methods. To boost worker well-being and operational efficiency, this study presents a clear framework that merges the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology with ergonomic risk assessment (ERA) methods. Traditional factory improvement efforts often overlook human factors, which significantly affect performance and defect rates. Instead, they focus solely on process quality or reducing costs. This study emphasizes the critical role of ergonomics in Six Sigma projects. The proposed methodology begins by identifying ergonomic risk factors in assembly and CNC machining tasks, using standardized evaluation methods like RULA, REBA, and NIOSH lifting indices. The DMAIC cycle is applied to statistically analyze the collected data to find connections with operator fatigue, process variation, and cycle-time inefficiencies. In the Analyze phase, quality losses are linked to specific ergonomic issues through statistical process control (SPC) and cause-and-effect analysis. Meanwhile, the Control phase uses post-intervention ergonomic scores and improvements in sigma levels to confirm changes. The Improve phase includes ergonomic redesign, workstation adjustments, tool modifications, and training efforts. To demonstrate the usefulness of the integrated model, a fictional case study simulates a CNC machining and automotive assembly line environment. The results show an increase of 0.5 to 1 sigma level in key process indicators and an expected 30 to 40% reduction in ergonomic risk exposure. The study provides a solid approach that combines Six Sigma quality management with human factors engineering. It fosters a culture of continuous improvement that enhances worker satisfaction, productivity, and safety. This integration framework offers practical insights for ergonomists, quality practitioners, and industrial engineers seeking to remain competitive in high-performance manufacturing environments.
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Copyright (c) 2026 Rosy Kolge, Dr. Avinash Somatkar, Manas Deshmukh, Krishna Hadole, Harshvardhan Ahire (Author)
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