By James D. Rethaber, Ph.D., CPE, LSSMBB
Vice President of Technical Operations, Fit For Work
If you are in the industrial setting, two terms you’ve probably encountered are “ergonomics” and “continuous improvement.” Ergonomics involves the interactions between human operators and the various elements of a system, with the goal of improving or optimizing the system—thereby enhancing human well-being, safety, and performance. Continuous improvement focuses on the ongoing refinement of products, services, and processes.
While the objectives of ergonomics and continuous improvement are similar, it would seem logical to assume that these initiatives are integrated. Unfortunately, that is not always the case. So, how can different approaches to systems-based improvement be combined for maximum impact?
In this blog, we’ll examine two distinct approaches—human-centric/collaborative and nonhuman-centric/working in parallel—compare their differences and explore how they can be integrated to strengthen your continuous improvement strategies.
Bridging Two Paths: Collaborative vs. Parallel Ergonomic Strategies
Understanding the differences between human-centric and nonhuman-centric approaches can reveal opportunities to integrate both for more effective continuous improvement.
Which Approach Yields Better Results?
After viewing the comparison between the two approaches, human-centric/collaborative provides the biggest benefit to the overall organizational system, as well as the human operator. By integrating ergonomics and continuous improvement, you are utilizing a holistic approach that improves both operational efficiency and worker health.
How to Integrate Ergonomics Within Continuous Improvement Initiatives: A Step-by-Step Guide
The question then becomes, “How do I integrate ergonomics within continuous improvement initiatives?”
Here’s a general guide that can be modified to fit your respective organization:
Step 1: Identify High-Impact Areas by Leveraging Existing Team Data
Determine the areas where you can make the biggest impact in the shortest amount of time. These “low-hanging fruits” may include processes or tasks that are relatively easy to improve while using the least number of resources.
To pinpoint these opportunities:
- Ergonomics Team: Use both proactive data (e.g., job observations, employee interactions, discomfort surveys) and reactive data (e.g., OSHA 300 logs, TRIR, loss runs) to identify ergonomic risks.
- Continuous Improvement Team: Analyze production runs, error rates, throughput, takt time, cycle time, and material costs to find process inefficiencies that can be quickly improved.
Step 2: Integrate Ergonomics and Continuous Improvement Teams Through Overlapping Opportunities
Form a unified, interdisciplinary team by combining the strengths and insights of both groups.
- Compare data identified in Step 1 to uncover opportunities that appear in both teams’ data. Considering these shared opportunities will allow the team to achieve multiple goals with a single action.
- If no overlap exists, collaboratively evaluate which opportunities are the most logical to prioritize. Consider factors such as:
- Physical proximity or shared location
- Availability of team resources
- Seasonal trends
Step 3: Begin Data Collection by Establishing a Clear Baseline
Before implementing any changes, gather baseline data to ensure improvements are measurable, targeted, and evidence-based.
- Ergonomics Assessments: Evaluate current risk levels to understand the strain on employees prior to making changes.
- Physical Demands Analyses: Objectively quantify the physical demands of each job task.
- Time Motion Studies: Measure how time is spent performing job duties to reveal inefficiencies and opportunities for improvement.
- Compare ideal vs. observed time
- Analyze throughput, takt time, and cycle time
- Determine cost implications such as labor, materials, consumables, etc.
Step 4: Apply the ADDIE Model
Use the ADDIE Model (Analyze, Design, Develop, Implement, Evaluate), a model “borrowed” from the instructional design world, but very adaptable and applicable to the work environment.
- Analyze: Review the data collected in Step 3 to identify key features.
- Design: Create recommendations or controls to ensure performance and productivity is improved without increasing the physical demands of the human operators or placing the safety of the human operators at risk.
- Develop: Build recommendations or controls based on the Design step in ADDIE Model.
- Implement: Put the developed recommendations into action, using the same criteria as Design step.
- Evaluate: Assess the effectiveness of the changes using tools such as:
- Conduct post-implementation ergonomics assessments
- Conduct updated physical demands analyses
- Re-run time motion studies
- Compare updated cost data to baseline figures
Conclusion
Integrating ergonomics within continuous improvement initiatives yields improved systems-level results, which not only leads to better financial outcomes for the organization, but also leads to the improved health, safety, and well-being of the human operators. Whether you’re getting started or looking to refine your approach, taking a human-centric, collaborative approach will lead to more sustainable, impactful results.
Ready to Improve Your Workplace?
If you’re ready to take the next step in optimizing your work environment, contact us today. We can help guide you through the process and provide customized solutions for your specific needs.
James Rethaber, Ph.D., CPE, LSSMBB, is Vice President of Technical Operations at Fit For Work. In his role he provides strategic direction for the Safety, Ergonomics, and Testing departments and initiatives. Dr. Rethaber also oversees the onboarding and continuing education initiatives to assist Fit For Work staff.
Prior to joining Fit For Work in 2007, Dr. Rethaber worked in the education and healthcare fields. He has over 20 years of experience in the fields of engineering, psychology, and musculoskeletal injury prevention, and has completed over 10,000 ergonomics-related assessments in nearly every industry.
Dr. Rethaber has a Bachelor of Science in Sports Medicine, a Master of Science in Exercise Physiology, a Master of Science in Industrial Engineering, a Master of Science in Applied Psychology, and a Ph.D. in Human Performance Technology.
He is a Board-Certified Professional Ergonomist (CPE) and is a Lean Six Sigma Master Black Belt. Dr. Rethaber serves on industry advisory boards at Texas A&M University – College Station and Texas State University – San Marcos and is a former member of the Board of Directors with the Board of Certification in Professional Ergonomics.
