Ergonomic Assessment of Manufacturing Industries: A Case Study of Small-Scale Industries

Abstract

This study focuses on the assessment of ergonomic risk factors in small and medium-sized enterprises, namely in machining, and assembly operations where workers are subjected to heavy physical handling, uncomfortable postures, and repetitive motions. The goal is to evaluate the risks of work-related musculoskeletal disorders (WRMSDs) and provide appropriate ergonomic solutions to enhance comfort, safety, and productivity. A variety of workstation postures and load-handling techniques were examined using standardized assessment instruments, including the NIOSH Lifting Equation, RULA (Rapid Upper Limb Assessment), and REBA (Rapid Entire Body Assessment).With REBA scores between 10 and 13, RULA scores between 7 and 8, and NIOSH Lifting Index values between 1.2 and 2.7, indicating hazardous lifting and postural situations, the results show that all procedures under investigation fall into the \"very high-risk\" category. Prolonged standing, high trunk flexion, repetitive wrist action, inadequate tool design, and the absence of mechanical assistance are major contributing causes. The quantitative results were corroborated by employee input, which revealed regular wrist, shoulder, and lower back pain. In order to reduce tiredness and prevent injuries, the study suggests worker training programs, mechanical handling systems, ergonomic tool development, and workstation redesign. By putting these strategies into practice, ergonomic hazards can be significantly decreased, productivity can be increased, and worker satisfaction can be raised. Overall, the study emphasizes the importance of ergonomics for improving occupational health and industrial sustainability in medium-sized enterprises.

Introduction

This study examines the importance of ergonomics in improving worker safety, comfort, health, and productivity in industrial environments. Ergonomics focuses on designing tools, workstations, and work processes that match human capabilities, helping reduce physical strain, fatigue, repetitive stress injuries, and musculoskeletal disorders (MSDs). By applying ergonomic principles, industries can improve employee well-being, operational efficiency, product quality, and compliance with workplace safety regulations.

The literature review highlights that ergonomic interventions—such as adjustable workstations, ergonomic tools, anti-fatigue mats, proper posture training, and improved human-machine interaction—significantly reduce injuries and increase productivity across manufacturing, mining, construction, textile, office, food service, and automotive industries. Recent research also emphasizes integrating ergonomics with Industry 4.0 technologies, wearable sensors, exoskeletons, and Lean Production Systems.

The experimental study was conducted in manufacturing industries in Kolhapur, India, including machining, sheet metal, foundry, and assembly industries. Ergonomic risk assessments were performed using REBA (Rapid Entire Body Assessment), RULA (Rapid Upper Limb Assessment), and the NIOSH Lifting Equation.

In the assembly industry case study, workers experienced prolonged standing, frequent bending, repetitive movements, and heavy lifting, resulting in lower back and wrist pain. The ergonomic assessments showed:

• REBA score: 12–13 (Very High Risk)
• RULA score: 7–8 (Very High Risk)
• NIOSH Lifting Index: 1.20 (Above the recommended safe limit)

These findings indicate an urgent need for ergonomic improvements. Recommended interventions include redesigning workstations, using mechanical lifting aids, introducing job rotation and rest breaks, providing ergonomic tools and personal protective equipment (PPE), and improving worker training.

Conclusion

This study demonstrates how crucial good ergonomics are to making medium-sized factories safer, more comfortable, and productive. It became evident that workers in assembly, machining, and casting jobs are at high risk due to poorly configured workstations when we examined the situation using techniques including REBA, RULA, and the NIOSH Lifting Index. They lift objects by hand, adopt strange postures, and repeat the same actions repeatedly. They may have fatigue, discomfort, and long-term issues with their bones and muscles as a result of these things. Workers in assembly, machining, and casting are under a great deal of physical stress, according to an examination of medium-sized manufacturers. This results from awkward postures, repetitive tasks, and poorly configured workstations. The majority of vocations are extremely dangerous for creating muscle and bone disorders, according to tests utilizing REBA, RULA, and the NIOSH Lifting Index. This demonstrates the urgency of resolving these workplace issues. Physical stress and fatigue can be significantly reduced by rearranging workstations, switching to more ergonomic tools, moving items using machines, and educating employees about safety. In addition to making employees safer and more comfortable, this increases productivity, reduces absenteeism, and improves the quality of the work.

References

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Copyright

Copyright © 2026 Avdhut Shahapurkar, Rahul Bhedasgaonkar, Sunil Jamadade, Kartik Khandagale, Pankaj More, Sakshi Jadhav, Rupali Jivtode, Sanskruti Sangavkar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.