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
Success Projects

Smart Supply-chain Resilience in Gear Shaft Machining
Responsive Supply-chain

Restructuring Production & Logistics in Heavy Gearbox Manufacturing
Flow Optimization

National-Level Demonstration of Visual Transparency in Special Steel
Flow Optimization

TPM & VSM Upgrade for Battery Quality Compliance
Flow Optimization