165 Ergonomic intervention for maintenance workers for an automatic production system: a case study

Abstract Introduction Automated equipment is essential in modern industrial operations for its high efficiency. The reliability of an automated system often depend on maintenance workers for ensuring that each equipment runs smoothly. In this case study, the maintenance department at an automated manufacturing facility suffered frequent equipment breakdowns. In addition to routine adjustment, maintenance workers often faced extra workload and stress dealing with troubleshooting sessions. This caused high turnover rate among the trained workers, which further increased workloads to the remaining crew members. Methodology Personal interviews were first conducted for the scope of problem. Subsequently, on-site observations were made with the maintenance tasks using Ovako working posture analysis system (OWAS) to assess possible ergonomic hazards. Additionally, service records from the previous 6 months at the facility were reviewed for cause of breakdown, and to assess whether there is a way to reduce the excess workload. Results Service records showed that the equipment was down nearly 50% of the time and tended to break down within 24 hours of scheduled maintenance. On-site observations showed that maintenance workers had to work in strenuous postures for extended time period that, upon completion of scheduled maintenance, workers tended to rush to end their tasks without final checks. After discussing with the workers, a checklist was constructed. Within a month the need for subsequent troubleshooting sessions went down substantially, and the equipment running time also increased to over 80%. Conclusions Ergonomic hazards can affect workers’ morale. By reconfiguring the task arrangement, equipment errors was greatly reduced. Workers’ participation in problem-solving process also proved helpful.