Application of TRIZ Methodology for Ergonomic Problem Solving in a Continuous Improvement Environment
This paper discusses a case from an automotive industry plant where ergonomic problems were identified corresponding to inadequate postures resulting from operations performed above the workers’ head height. Company’s economic situation didn’t allowed to
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Abstract This paper discusses a case from an automotive industry plant where ergonomic problems were identified corresponding to inadequate postures resulting from operations performed above the workers’ head height. Company’s economic situation didn’t allowed to consider the automation of the operation despite the recognized need to reduce or, ideally, to eliminate the risk to operators. In this context the use of the TRIZ methodology offers an opportunity to identify potential solutions. Therefore, the TRIZ’s Su-Field Analysis was used, with the support of an adapted Contradiction Matrix. This approach allowed obtaining a more structured solution, combining Ergonomics with Lean management principles. The outcome of implementing the proposed solution was the elimination of wastes and the improvement of workplaces’ ergonomic quality. Furthermore, the study provided some insights on ways of eliminating or reducing existing Occupational Safety issues in the near future. Keywords Occupational safety
Problem solving Su-Field analysis
J.F. Alves Department of Mechanical and Industrial Engineering, Faculty of Sciences and Technology, Universidade NOVA de Lisboa, 2829-516 Caparica, Portugal e-mail: [email protected] H.V.G. Navas I.L. Nunes (&) UNIDEMI, Department of Mechanical and Industrial Engineering, Faculty of Sciences and Technology, Universidade NOVA de Lisboa, 2829-516 Caparica, Portugal e-mail: [email protected] H.V.G. Navas e-mail: [email protected] © Springer International Publishing Switzerland 2016 P. Arezes (ed.), Advances in Safety Management and Human Factors, Advances in Intelligent Systems and Computing 491, DOI 10.1007/978-3-319-41929-9_43
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1 Introduction Some industries still have a large dependence on manpower. For instance, in automotive manufacturing not all the tasks are performed by robots. Besides the reasons related with the high costs of automating some processes, some operations are very difficult to automate with the available technology, namely the ones related with the assembly/trimming processes. However, this draw upon manpower may have unexpected costs, since any ergonomics inadequacies in medium and long term may cause musculoskeletal disorders [1]. One of the purposes of Lean philosophy in manufacturing is to reduce the variability of processes, turning the planning process much more accurate and allowing the reduction of waste. Several authors refer that lean implementation can take a toll on workers since its goal is to maximize production minimizing resources, which can affect working conditions and promote work-related musculoskeletal disorders (WRMD) [2]. WRMD, which are associated with repetitive and strenuous working conditions, continue to represent one of the biggest occupational problems in companies causing absenteeism [3]. WRMD are caused by physical, psychosocial, and individual risk factors. Psychosocial and individual risk factors are assumed as transversally contributing factors, which are not important enough to produce by themsel
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