Ergonomics- Toyota’s Motor Manufacturing Assembly

Task Prior to Abatement (Description)

Workers had to perform auto plants normal production assembly. The tasks involve various postures, reaching distances, pinching or gripping, and manual lifting.

Task Prior to Abatement (Method Which Identified Hazard)

There were an increasing number of work-related injuries and illnesses, most of which related to upper extremities.

Ergonomic Risk Factor (Posture)

Workers had excessive forward bending to perform a task.

Workers had to climb inside a car to install a part.

Ergonomic Solution (Administrative Controls)

Record keeping was made easier.

Training programs were provided.

Job rotation program was set.

CTD detection and early prevention were incorporated in the ergonomics intervention program.

Personal protective equipment, physical therapy, and workplace accommodations were provided.

With indication of early symptoms of CTDs, workers are sent to industrial health services for a medical evaluation.

Ergonomic Solution (Engineering Controls)

An automated chair for moving the seated worker in and out of the vehicle has been developed.

The work surface has been tilted to minimize the worker’s forward bending.

Ergonomic Solution (Benefits)

All workers that perform the tasks now have reduced exposure to CTDs.

Reduction in workers’ compensation costs.

Ergonomic Solution (Method Which Verified Effectiveness)

CTD-related incidents have been reduced by implementing ergonomics interventions.

Comments

This ergonomics evaluation system, although argued to be too subjective, pinpoints problem areas before they become critical.

Source

CTD News, 1995, Toyota’s Evaluation, Ergonomics that work, CTD News.


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