Posture-Based Risk Assessment for Improvement of Physical Workload: Case Study for an Assembly Line

Abstract

Ergonomic risk assessment is required to prevent work-related musculoskeletal disorders. Some assessment techniques in a broad range of complexity have been suggested. A complex tool quantifies a detailed risk, but it is time-consuming. In this study, a simple risk assessment method is proposed to improve (Kaizen) production line work by lowering the physical load on the worker. This method is based on Rapid Entire Body Assessment (REBA), but it can be used not only for posture analysis, but also for consecutive repetition work in any production line. A station work unit is divided into work elements. Two posture scores per work element are estimated for the upperlimbs as well as for the head, trunk and legs, respectively. Physical workload on the work unit is obtained from the weighted average of workloads on consecutive work elements applying a tact time. The daily workload is also examined for the workload on work units and production planning. The validity of the proposed method is investigated by an assembly line of vending machines for case study.