Managing the Risk of Biomechanical Overload of the Upper Limbs in a Company that Produces High-End Clothing for Men

Abstract

The manufacturing facility that is the subject of this case study, where around 300 workers work, is organised by department (cutting, sewing, pressing, final testing) and has an incentive system based on the individual performance of each worker, which is calculated with respect to the standard timeframe needed to carry out operations.

The study carried out will analyse how risk indicators pertaining to biomechanical overload of the upper limbs vary in relation to the following factors:

• trends in the individual performance of workers with regard to individual operations

• rotation of personnel through various operations with differing risk indicators

• time that workers are exposed to different operations

• the inverse proportion between worker performance and times during which workers maintain inappropriate posture in each joint area

Due to the way in which all production cycle operations are mapped out, software has been implemented to enable users to manage risk in production departments in a more efficient and effective way.

In particular, via the integration of this system with the management system previously in use at the company, it is possible to obtain data relating to:

• the actual presence of workers in individual workplaces

• performance of workers in individual workplaces

As a result, it is possible to measure an individual worker’s actual exposure to risk during an entire work shift.

Thanks to risk indicators being updated in real time, managing the rotation of personnel in production departments is improved. This also provides the versatility needed to balance times that workers spend carrying out operations with varying levels of risk.