This study aims to map and analyze ergonomic risk factors in a manufacturing company’spacking department. Based on the found ergonomic risk factors, the study aims to find potentialsuggestions for improvement. The company on which the work is carried out requires that theproposal measures do not adversely affect the efficiency of the packing lines. To enable amapping of the variants that make up the largest volume in the process, the question is firstanswered, 

1. Which pack variants make up the largest volume in the packing department for sawsand how the weight is distributed between the pack variants?  

By using ABC analysis, a categorization of all 156 pack variants that are packed in thedepartment were made. The analysis categorizes all pack variants into three categories, A, Band C, based on its volume. The result of the performed analysis generated 31 pack variants inthe A category. The pack variants in category. The categorization was then further categorizedinto three categories based on the weight of the chainsaw. The categorization is made to formcategories that are possible to study ergonomic risk factors for the study’s second question.

2. Which are the main ergonomic risk factors for the pack variants that are most criticalto the company?

To map the different ergonomic risk factors in the different weight categories, frequencyanalysis was made. During the implementation of the frequency studies, it is assessed whichworking position the operator works in and how critical it is, based on the ergonomicperspective. Frequency analyses are made on the three different weight categories that wereestablished in the study. When the completion of the frequency analysis was made, the datafrom them were compiled into an FMEA-analysis. The FMEA results in a number of failuremodes that exceed an RPN value over 200 and are thus considered critical. For the failuremodes that exceed an RPN value of 200, measures were investigated in the studies thirdquestion. 

3. How can the process be improved based on ergonomic perspective based on theidentified ergonomic risk factors, without negatively affecting the efficiency of theprocess?

The proposed measure for the critical ergonomic risk factors was investigated throughbenchmarking. Internal benchmarking was made by observing other parts of the company.Potential proposed measures were also investigated through external benchmarking at variousretailers. The time impact of the proposed measures is assessed based on time studies and howthey affect the RPN values of the failure modes. After an evaluation of the proposes measures,these are combined into final solution proposals for the department’s two packing lines.