Designing an Ergonomic Experience Zone – Where People Meet Processes

Client
Hager Group, China
Date
April 08, 2024
Services
Agility Operations | Delivery Transitional Leadership
Website

Major Improvments

  • Muri & Ergonomics Simulation Station
    Created real-life workstations simulating repetitive tasks to assess physical strain using posture scanning and force sensors.
  • Body-Machine Interaction Visuals
    Displayed common ergonomic risks and good practices via physical demo stations and interactive screens.
  • Operator Co-Creation Sessions
    Engaged frontline workers in co-designing improved tools and workstation heights for better fit and safety.
  • Lean-Linked Ergonomics Metrics
    Integrated injury risk scores and fatigue indicators into the daily management board.

Application Scope

  • Production Line Redesign
    Used simulation data to redesign tool layouts and lifting supports across 3 engine assembly lines.
  • Operator Training & Awareness
    Standardized ergonomic onboarding for new hires, reducing complaint rate by 38%.
  • Health & Safety Campaigns
    Built the zone into HSE Week activities to reinforce safe and sustainable working behavior.
  • Improvement Project Validation
    Acted as a testbed for ergonomic Kaizens before rolling out changes to real workstations.

Customer Says

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