Cost effectiveness of ergonomics and quality improvements in electronics manufacturing

This paper describes the increasing emphasis on ergonomics in the manufacturing plants of IBM. Since 1978, 250,000 engineering hours have been devoted to ergonomics training. As a result a systematic approach to ergonomics improvement of manufacturing facilities has been implemented. This involves an analysis of the production environment including equipment, processes, ambient factors and job procedures. Information is collected through interviews of management, operators, and first-line supervisions, and complemented thorough field measurements of ergonomic parameters. Individual workstations as well as processes are analyzed with the purpose of modifying processes, reallocating tasks between automated devices and human operators and optimizing workstation design. Four case studies of industrial improvements are presented and analyzed in terms of improved productivity, quality, and reduction of injuries. All four studies proved to be good investments. Since its implementation around 1978, it is estimated that ergonomics improvements have resulted in cost savings of approximately $130 million. Relevance to industry Ergonomics improvements of four industrial processes are described. The main emphasis was to improve production, and manufacturing yield. The primary economic benefits were derived from improvements in productivity and quality. There were also improvements in injury rates and operator satisfaction.