ZERO FATIGUE IN MANUFACTURING

Improved Safety

 Increased Productivity

Worker Health

ZERO FATIGUE VISION

According to the American College of Occupational and Environmental Medicine, fatigue in the workplace can result in “slowed reaction time, reduced vigilance, reduced decision-making ability, poor judgment, distraction during complex tasks, and loss of awareness in critical situations.” To tackle such activities there are different varieties of fatigue management methods to tackle these, some of them are ergonomics tools

Ergonomics and  Work-Place Design: According to a recent survey, the major reason for low productivity in the manufacturing industry is the health-related problems of the workforce and Safety concerns of workers. In layman’s terms, Ergonomics means fitting the job to the worker’s capabilities or One can say Ergonomics is the science of designing the job to fit the worker, rather than physically forcing the worker’s body to fit the job.

TYPES OF ERGONOMICS

Physical Ergonomics

Physical Ergonomics

cognitive ergonomics

Cognitive Ergonomics

organizational ergonomics

Organizational Ergonomics

BENEFITS OF ERGONOMICS

1. Improved Safety – The most common issue being faced in an industry is the injuries of the workers. Ergonomics reduces the risk of workers’ injury and improves overall safety.

2. Increased Productivity – Ergonomics evaluations primarily aim at decreasing the risk factors but somewhere it also helps in increasing productivity.

    For Example     

A worker in Factory A – Lifts the items from the floor to place them on the other side.

A worker in Factory B – With the help of an ergonomically designed Machine the items are bought within the reach of the worker without pinching, pushing, or pulling. So, In Factory B the improved work process resulted in decreased cycle time by 10%, which results in increased productivity.

3. Worker Health – Bending, Twisting, Turning, and Heavy lifting results in painful injuries to the workers. Effective ergonomics reduce the risk of worker injury and maintains or improves their health allowing workers to perform their work and enjoy an improved quality of life outside of work.

There are many other benefits of the Ergonomic Manufacturing Process in an Organization.

MANUFACTURING EXCELLENCE IMPLEMENTATION PROCESS

OBJECTIVE : 

Zero Fatigue: Fatigue is a workplace hazard and can be associated with the safety and health of the worker. It affects the health and safety of the employee.

EXAMPLES

  • Scope Defining
  • Workplace Ergonomics Analysis different Technical Score (REBA, RULA, WAS, HARM, NIOSH, JSI, KIM, EAWS, RAMP)
  • OFI(Opportunities of Improvements) Points Sharing
  • Support in Workplace Design Modification
  • Final Audit

OBJECTIVE : 

Employee Engagement: To improve workplace conditions that drive engagement and enhance employee sense of well-being.

EXAMPLES

  • Basic 5S Awareness
  • 1S, 2S Implementation
  • Workplace Visual Management (Visual Factory)
  • Kaizen Strategy Implementation
  • Suggestion Scheme
  • Innovative Leaders

    OBJECTIVE : 

    Zero Breakdown: Maintenance is all about working for the ultimate goal with a winning maintenance strategy.

    EXAMPLES

    • My Machine Campaign
    • CLIT
    • Machine Utilization Monitoring
    • Machine Losses Reduction
    • Breakdown Analysis
    • Preventive Maintenance
    • 3S ,4S & 5S for Machine & Office area

    OBJECTIVE : 

    Zero Waste: To eliminate waste across entire waste value chains to the fullest extent possible through reuse and recycling. Zero Waste is more than just a problem of disposal but a need to reduce harm encompassing the entire life cycle of a product.

    EXAMPLES

    • Time & Motion Study
    • Lean Layouting
    • ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)
    • Material Handling Optimization
    • OEE/ OLE

    OBJECTIVE :

    Zero Accident: The risk of falling, risks related to electricity or handling of machinery, road hazards, and more. Every day, the awareness of each and every employee is essential to avoid accidents in the workplace and to prevent occupational illnesses.

    EXAMPLES

    • OH & S Management System Implementation
    • Safety KPIs
    • Workplace & Safety
    • HIRA
    • Safety Signage Standardization

    OBJECTIVE : 

    Zero Effect: To make the production process, product, environment friendly and good enough for social well-being and sustainability of the environment.

    EXAMPLES

    • Environment Policy
    • Effect Impact Analysis & Life Cycle Assessment
    • Energy Cost Optimisation
    • Waste Management & Control

    OBJECTIVE : 

    Zero Defect: Developing a product that has no defects but ensuring the quality standards and reducing the defects to a level of zero in your projects.

    EXAMPLES

    • Quality Management System Awareness
    • Quality Performance (Quality KPI Development &  Tracking )
    • Non-Conformities Identification & CAPA Implementation
    • Workplace Audit
    • 7 QC Tools & 7 Management Tools
    • Problem Solving & Poka Yoke
    • Root Cause Analysis

    OBJECTIVE : 

    Zero Loss: Zero Loss” is an aim/attempt to overcome such losses or minimize their effect up to great extent in order to reduce the manufacturing cost

    EXAMPLES

    • Advance Lean Practices Implementation
    • Manpower Rationalization
    • Design & Process FMEA
    • APQP
    • Line Balancing

    OBJECTIVE : 

    Zero Delivery / Failure: To accomplish the task within the lead time without failure in inventory time, WIP storage, logistics cost, and mapping of the steps a company takes to complete a certain process.

    EXAMPLES

    • Value Stream Mapping
    • Value Supply Chain Management
    • Inventory Analysis & Management
    • Process Mapping (BPM/BPR)

    OBJECTIVE : 

    • 100% Sustenance

     

    EXAMPLES

    • Employee Training & Re-Training
    • DOJO Set-up
    • Training Content