Redesign of work-accessories towards minimizing awkward posture and reduction of work cycle elements in an Indian shop-floor workstation

Abstract

Indian plastic processing industry comprises of Micro, Small and Medium Enterprises (MSMEs). Manual labor and locally designed workplace fixtures are observed in shop-floor workstations. Aim of present research was to identify incidence of musculoskeletal ailments and awkward working postures among workers in the granulator workstation and propose design modifications from physical ergonomics perspective. Combination of research techniques comprising of questionnaire study, postural assessment tools, statistical analysis, digital human modeling and method study were utilized to accomplish the stated objective. Significant occurrence of body part discomfort was observed. Workstation accessories designs were not in accordance with recommended guidelines. Workstation design and work methods were found incompatible with worker’s anthropometry and thus led to the prevalence of awkward working postures. Redesign of workstation accessories and subsequent modification of work methods, enabled improvement of working postures and reduction of work elements. Research methodology demonstrated in present study may be adopted by engineers/ managers/supervisors in MSMEs towards implementing context specific human centric production systems.