Ergonomic improvements gohand in hand with productivityin a logistic environment

INCOSE| September 14-16, 2016

D. Delaruelle, O. Wanten, S. Acke

2 | 21-9-2016

Dirk Delaruelle Head of the Ergonomics Department

dirk.delaruelle@mensura.be

ScopeConsiderations

Interventions related to sustainable employability

� Often focus on one person

� Are mostly related to

� Job content (work restrictions)

� Job organization (working part-time)

� Specific equipment (workplace, tools)

3 | 21-9-2016

Aim of ergonomics

� To design or arrange workplaces, products and systems so that they fit

the people who use them throughout their careers.

ScopeDefinition of Ergonomics

Ergonomics (or human factors) is the scientific discipline concerned

with the understanding of the interactions among humans and other

elements of a system, and the profession that applies theoretical

principles, data and methods to design in order to optimize human

well being and overall system performance

www.iea.cc www.besweb.bewww.eurerg.euwww.ergonomics-fees.eu

4 | 21-9-2016

5 | 21-9-2016

ScopeNeovia Logistics Houthalen

European logistic distribution center of Harley Davidson

� Medium sized company, 60 employees

Outbound process, 3 flows

� Large, medium and small parts

Activities in outbound process

� Picking

� Collecting

� Packaging

� Labeling

� Shipping

6 | 21-9-2016

Large PartsPicking process

in generalOutbound area

Scope

- Difficult to handle

- Too many

manipulations

- Peak load problems - Plenty of problems

- Eliminating pigeon

holes

Aim of the project

� Improve capacity of outbound area

� Improve productivity of process

� Improve working conditions

Value stream transformation project

7 | 21-9-2016

Project organizationGeneral set-up

Neovia point of view

� Project work – Participatory approach

Project groupParticipatory

approachErgonomics

Project group

Participatory approach

� Incorporation of ergonomics from the beginning

Ergonomic approach Philosophy From advice to solutions

Work

me

tho

d

Org

an

isa

tio

nal

SOLUTIONS

PA

RT

ICIP

AT

OR

Y

MU

LT

IDIS

CIP

LIN

AIR

Work conditions

Technical

INVESTIGATION

9 | 21-9-2016

3 Step approach – From advice to solutions

1. Observation of outbound area

� Understanding the process, flow

� Tasks performed, workload

� Pictures, video’s

2. Participatory group discussion

� With operators and operational management

� Difficult tasks, their proposals, their preferences

3. Multidisciplinary discussion

� Choose between options, fine-tuning

� Generate new solutions

� Commitment

Follow-up on the adjustments

� Participatory approach, 2 follow-up visits

Ergonomic approach

10 | 21-9-2016

General set-up

Multidisciplinary project group

� Project manager

� Plant manager

� Operations manager

� Facility manager

� Security officer

� Ergonomist

Participatory approach

� Involvement of operators at different moments

Ergonomic approach

Ergonomics

Project Group

Participatory approach

11 | 21-9-2016

BeforePigeon holes

Situation before: pigeon holes

� Buffer place for small and medium parts to collect them

12 | 21-9-2016

BeforePallet boxes

Situation before: pallet boxes for higher volumes

� From different carts: large and medium parts

13 | 21-9-2016

BeforePallet boxes

Situation before: pallet boxes for higher volumes

� From different carts: large and medium parts

Back-up slide … for video

14 | 21-9-2016

- Adapting flow and

work organization

- Conditioned at

moment of picking

- Directly to shipping

area

- Optimize organization

by reducing peak load

- Specific new BIN cart

- Most ergonomic

improvements

- New workstation

- Packaging table

- Flow, pigeon holes

eliminated

Large PartsPicking process

in generalOutbound area

RealizationsGeneral overview

15 | 21-9-2016

Bin cart picking process

Proposition - solution

Realizations

16 | 21-9-2016

Proposition - solution

RealizationsBin cart picking process

17 | 21-9-2016

Workstation and packaging table

Small basic workstation

Movable packaging table

Less options cardboard boxes

Realizations

18 | 21-9-2016

Movable

packaging

table with

two levels

Workstation and packaging table

Realizations

People related

� Less need of interim operators

� Reduced learning time by 50%

� At peak moments operators do not feel increased work load

� Subjective feeling of operators: reduction of workload

Results

Capacity outbound area

� Less buffer by better wave management

� Less peak moments

� Increased capacity

Productivity

� No increased productivity goals for each task

� Productivity increased with 15%

Work smarter not harder

Results - outbound productivity in 2013100% is the average productivity of the 12 months before the project

First adjustments in July and October 2012

Major lay-out changes in February 2013

All adjustments finished in April 2013

Results 2012

Target 2013

Results 20132013 average

21 | 21-9-2016

Ergonomic interventions and improving work conditions =

facilitating return to work interventions

Benefit for small companies

Importance of affordability

Three step approach = very to the point

Open mind discussions in multidisciplinary project groups

Follow-up to secure and optimize the solutions

Conclusions

This project won the prize "Health and Company 2014" of the

European Club for Health Promotion (Belgian section)

22 | 21-9-2016

Questions? Remarks? Just contact …

Dirk Delaruelle

Scan QR for abstract