Design and implementation of a participatory ergonomics program for machine sewing tasks

A participatory ergonomics program was designed and implemented to control and reduce workers' compensation costs within an automobile products manufacturing company. Pareto analysis identified a substantial number of musculoskeletal disorders (MSD) associated with manual, machine sewing of canvas automobile accessory products. This case study will discuss the elements of the participatory ergonomics program, describe its implementation, highlight intervention measures, and present program results. Specifically, during the period of 1993 to 1996, the participatory ergonomics program played a significant part in reducing the number of MSD claims by approximately 85%, and contributed to an overall reduction in workers' compensation incurred loss costs by approximately 42%. Relevance to industry The operations of a manufacturing company are highly interrelated. Therefore, a participatory ergonomics program, with multi-disciplinary representation, is one approach by which a company can weave together its risk management objectives of quality, productivity, safety, and cost containment so as to achieve effective production while simultaneously preventing injuries and illnesses.